Crown Forklifts Models Service Repair Manuals
Catalog:
Model:
Complete repair service manual for Crown Forklifts, with all the workshop information to maintain, diagnose, and repair like professional mechanics.
Crown Forklift Trucks workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 6,122 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
MANUAL LIST:
ESR
ESR4000.pdf
ESR4500.pdf
FC_FP
FC4000
9A136341.PDF
9A999999.pdf
Codes M4.2-2040-400.pdf
DIA-2040-057.pdf
HYD-2040-001.pdf
M4.2-2040-001.pdf
Maintenance M1.0-2040-001.pdf
Pot Calibration M4.3-2040-200.pdf
Tune up M4.2-2040-200.pdf
FC4500
Access 123 M4.3-2045-001.pdf
Brakes M5.0-2040-001.pdf
Componentry M1.0-2045-050.pdf
DIA-2045-001.pdf
Distribution board M4.3-2045-100.pdf
Drive unit M3.0-2045-001.pdf
Electrical M4.1-2720-001.pdf
Event codes M4.8-2045-001.pdf
FC4500 Photo.doc
Glossary M10-2045-001.pdf
HYD-2045-001.pdf
Hyd circuitry M2.0-2045-050.pdf
Hyd system M2.0-2045-001.pdf
Lube and Adjustment M1.0-2045-001.pdf
Maintenance M1.0-04.0-001.pdf
Switches M4.0-2040-020.pdf
FC - FP
1A118490 HYD.pdf
1A125563.pdf
1A130541 HYD.pdf
1A142116.pdf
1A163514.pdf
9A104518.pdf
9A105298.pdf
9A108776 HYD.pdf
9A116236.pdf
9A999999-2 HYD.pdf
9A999999 HYD.pdf
9A999999.pdf
Codes M4.2-20.0-400.pdf
DIA-20.0-127.pdf
DIA-20.0-201[1].pdf
Lube and adj M1.0-20.0-001.pdf
Tune up M4.2-20.0-200.pdf
GPC
GPC2000.pdf
GPC3000.pdf
GPW
DIA-17.1-005.pdf
Early DIA-17.0-004.pdf
MS-GPW1000.pdf
LP
LP3010_3020.pdf
MCROMISCOPEK.zip
NOVA -sellfy(KudA84lgfpDg02x0L3HK).txt
PE
PE
Codes Sevcon M4.2-06.5-420.pdf
Resistor 6A101241.pdf
SCR EV1 H-007847.pdf
SCR Sevcon 6A101241.pdf
SCR Sevcon 6A109690.pdf
Transistor 6A999999.pdf
Troubleshooting Curtis M4.2-06.5-400.pdf
Tune up Curtis M4.2-06.5-210.pdf
Tune up Sevcon M4.2-06.5-200.pdf
PE 3000
HYD-6535-050.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-6435-001.pdf
Resistor 6A132473.pdf
Resistor 6A202946.pdf
Resistor 6A999999.pdf
Transistor 6A203155.pdf
Transistor 6A999999.pdf
Troubleshooting Curtis M4.2-6535-400.pdf
Troubleshooting Sevcon M4.2-06.5-420.pdf
Tune up Curtis M4.2-06.5-210.pdf
Tune up Sevcon M4.2-06.5-200.pdf
PE 4000
BDI.pdf
Lube and adj M1.0-6540-001.pdf
PE 4000 DIA-6540-001.pdf
Troubleshooting M4.2-6540-400.pdf
Tune up M4.2-6540-200.pdf
PE 4500 ac
Access 123 M4.3-6545-001.pdf
Codes M4.8-6545-001.pdf
DIA-6545-001.pdf
Electrical System M4.1-2720-001.pdf
Glossary M10-6545-001.pdf
Lube and adj M1.0-6545-001.pdf
PE 4500 Photo.doc
PR
60PR
DIA-06.7-534.pdf
PR3000
Curits M4.2-06.5-210[1].pdf
DIA-6730-200[1].pdf
Sevcon Transistor M4.2-06.5-420[1].pdf
PW3500
Resistor DIA-6435-200.pdf
Transistor DIA-6435-200.pdf
RC
30RC
1986 W models DIA-10.0-032.pdf
1989 H model DIA-10.0-039.pdf
Codes M4.2-14.0-400.pdf
DIA-10.0-072.pdf
Late models DIA-10.0-072.pdf
Troubleshooting EV 100 M4.2-10.0-400.pdf
Tune up M5 M4.2-10.0-200.pdf
Tune up MT M4.2-10.0-200.pdf
RC3000
Brakes M5.0-10.0-020[1].pdf
DIA-1030-030.pdf
HYD-1030-001.pdf
Lube and adj M1.0-1030-001.pdf
Trouble codes M4.2-14.0-400.pdf
Tune up M4.2-10.0-205.pdf
RC 5500
Access 123 M4.3-1055-001.pdf
Componentry M1.0-1055-050.pdf
Control Modules M4.3-1055-500.pdf
DIA-1055-001.pdf
Electrical M4.0-1055-001.pdf
Electrical Wiring M4.1-2720-001.pdf
Event Codes M4.8-1055-001.pdf
Glossary M10-1055-001.pdf
HYD-1055-001.pdf
Hydraulic M2.0-1055-001.pdf
Lube and adj M1.0-1055-001.pdf
Lube and adj M1.0-1960-500.pdf
Motors M4.7-1055-001.pdf
Parking Brake M5.0-1055-001.pdf
RC 5500 cover .doc
RR
35-45RRTT
1A999999 DIA-14.0-077.pdf
Codes M4.2-20.0-400.pdf
Dual lift HYD-14.0-254.pdf
H-14898 EV-1 DIA-14.0-049.pdf
H-999999 DIA-14.0-070.pdf
HYD-14.0-005.pdf
Lube and Adj M1.0-04.0-001.pdf
Sequencing Troubleshooting M4.3-1430-001[1].pdf
Troubleshooting M4.9-14.0-001.pdf
Tune up EV100 LX M4.2-14.0-200.pdf
Tune up EV100 M4.2-10.0-200.pdf
W-097841 DIA-14.0-063.pdf
RR 3000
DIA-1435-001.pdf
Glossary M10-1430-001.pdf
HYD-1430-001.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-1430-001.pdf
RR3520 card settings.pdf
Troubleshooting M4.2-14.0-400.pdf
Tune up M4.2-1435-200.pdf
RR 5000
Codes M4.3-1450-480.pdf
DIA-1450-001.pdf
HYD-1450-050.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-1450-001.pdf
Set up M4.2-1450-200.pdf
Set up Ver 06 M4.2-1450-218.pdf
RR 5200
24V HYD-1452-001.pdf
36V HYD-1452-050.pdf
5200 Manual
36V HYD-1452-050.pdf
Brakes M5.0-1452-001[1].pdf
Codes Ver 17 M4.3-1452-800.pdf
Componentry M1.0-1452-050.pdf
DIA-1452-001.pdf
Drive Unit M3.0-1452-001[1].pdf
Lift Chains M7.5-18.0-001[1].pdf
Lube and Adj M1.0-1452-001[1].pdf
Brakes M5.0-1452-001.pdf
Capacity Data Monitor M4.3-1452-200.pdf
Codes Ver 14 M4.3-1452-800.pdf
Codes Ver 17 M4.3-1452-800.pdf
Componentry M1.0-1452-050.pdf
DIA-1452-001.pdf
Drive unit M3.0-1452-001.pdf
Glossary M10-1452-001.pdf
Height Sensor M4.3-1452-300.pdf
Hyd Maintenance M2.4-1452-001.pdf
Hyd Manifold M2.4-1452-001.pdf
Hydraulic Circuits M2.0-1450-020[1].pdf
Hydraulic System M2.0-1452-001[1].pdf
Hyd sys M2.0-1452-001.pdf
Intro .pdf
Lift Cylinder M8.0-1452-001.pdf
Lube and Adj M1.0-04.0-001.pdf
Mast M7.0-1452-001.pdf
Multifunction Handle M4.5-1452-001.pdf
Reach Assembly M9.0-1452-001.pdf
Set up Ver 17 M4.3-1452-001.pdf
Steering System M6.0-1452-001.pdf
Tilt Cylinder M8.6-1452-001.pdf
RR 5200 AC
Codes Ver 07 M4.3-1452-800.pdf
DIA-1452-300.pdf
HYD-1452-050.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-1452-001.pdf
Set up M4.3-1452-700.pdf
TSB0391.pdf
TSB0407.pdf
TSB0426.pdf
RT
MS-RT3010.pdf
MS-RT3020.pdf
SC
35SCTT
1A117705 DIA-11.0-057.pdf
1A119678 DIA-11.0-057.pdf
1A1999999 HYD-11.0-005.pdf
1A999999 DIA-11.0-071.pdf
EV100 LX M4.2-10.0-001.pdf
EV100 M4.2-07.2-001.pdf
EV1 system.pdf
H-004404 HYD-11.0-003.pdf
H-012664 DIA-11.0-033.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-11.0-001.pdf
Troubleshooting EV100 LX M4.2-14.0-400.pdf
Troubleshooting EV100 M4.2-10.0-001.pdf
Troubleshooting M4.9-11.0-001.pdf
Tune up EV100 LX M4.2-10.0-205.pdf
Tune up EV100 M4.2-10.0-200.pdf
W-019323 DIA-11.0-009.pdf
W-025462 HYD-11.0-004.pdf
9A133624 DIA-1140-001.pdf
9A999999 DIA-1140-014.pdf
Lube and adj M1.0-1140-011.pdf
Lube and adj M1.0-1145-025.pdf
M4.2-1140-001.PDF
M4.2-1140-200.PDF
M4.2-1140-400.PDF
M4.3-1140-006.pdf
MS-SC3000.pdf
Pot Calibration M4.3-1140-200.pdf
SC3200.pdf
SC 4000
9A133624 DIA-1140-001.pdf
9A999999 DIA-1140-014.pdf
HYD-1140-001.pdf
Lube and adj M1.0-1140-001.pdf
Lube and adj M1.0-1140-011.pdf
Pot Calibration M4.3-1140-200.pdf
SC 4000 Trouble codes M4.2-1140-400.pdf
Tune up M4.2-1140-200.pdf
SC4000.pdf
SC 4000 Trouble codes M4.2-1140-400.pdf
SC4500 ac
Access 123 M4.3-1145-001.pdf
AC Traction M4.3-1145-600.pdf
Brakes M5.0-1145-001.pdf
DIA-1145-001.pdf
Electrical Wiring M4.1-2720-001.pdf
Event Codes M4.8-1145-001.pdf
Glossary M10-1145-001.pdf
HYD-1140-001.pdf
HYD-1145-001.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-1140-001.pdf
Lube and adj M1.0-1145-025.pdf
SC4500 Brake release F016819.pdf
SC4500 Photo.doc
SC4500 Brake release F016819.pdf
Tune up M4.2-1140-200.pdf
SP
30 SP
1A107566 DIA-07.4-060.pdf
1A1999999 DIA-07.4-071.pdf
1A999999 HYD-07.3-001.pdf
H-004758 DIA-07.3-003.pdf
H-999999 HYD-07.3-001.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-07.4-015.pdf
Switches M4.0-07.3-020.pdf
Troubleshooting EV100 M4.2-07.2-400.pdf
Tune up EV100 M4.2-07.2-200.pdf
W-010602 DIA-07.3-001.pdf
W-073305 EV-100 DIA-07.2-040.pdf
W-999999 HYD-07.3-001.pdf
Wire Guidance
Alignment M4.3-18.0-840[1].pdf
Line Driver M4.3-18.0-840[1].pdf
Pos Pot M4.3-18.0-770[1].pdf
Sensor Amp M4.3-18.0-680[1].pdf
Sensor Operation M4.3-18.0-660[1].pdf
Servo Amp M4.3-18.0-700[1].pdf
Servo Driver M4.3-18.0-720[1].pdf
System operation M4.3-18.0-540[1].pdf
Theroy of Operation M4.3-18.0-560[1].pdf
Wire guidance system M4.3-18.0-500[1].pdf
CROWN SP 3400
Accumulator.pdf
Battery.pdf
Brake 1.pdf
Brake 2.pdf
Cleaning of Material Handling Equipment.pdf
Componentry.pdf
Contactor.pdf
Control Module.pdf
Control of Hazardous Energy.pdf
Cyl Repair.pdf
Display and Steering Module.pdf
Display and Steering Modules.pdf
Drive Unit.pdf
EE Contractor.pdf
Electrical Diagrams Index.pdf
Electrical Wiring.pdf
Encoders.pdf
Event Codes.pdf
Fork Inspection.pdf
General Maint.pdf
Glossary.pdf
Hyd Schematic.pdf
Hyd Schematic Symbols.pdf
Hyd System.pdf
Intro.pdf
Lift Chain.pdf
Lift-Lift Lower Control Valve.pdf
Lubrication and Adj 1.pdf
Lubrication and Adj 2.pdf
Mast Maint.pdf
Mast.pdf
Motor Monitoring System.pdf
Motors.pdf
Platform Height Sensor.pdf
Platform Maint.pdf
Platform.pdf
Pump Lift.pdf
Relays.pdf
Skid Inspection.pdf
Steering Feedback.pdf
Steering.pdf
Torque Values.pdf
Troubleshooting Chart.pdf
Tune Up.pdf
Wire Guidance 2.pdf
Wire Guidance 3.pdf
Wire Guidance Line Drive.pdf
Wire Guidance.pdf
Wiring Diagram Intro.pdf
SP 3000
Codes M4.2-7330-600.pdf
DIA-7330-025.pdf
HYD-7330-001.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-7330-015.pdf
Transistor Panel M4.2-7330-001.pdf
Tune up M4.2-7330-210.pdf
SP 3000 series part 1.service.parts.uk.pdf
SP 3000 series part 2.service.parts.uk.pdf
SP 3200
Codes M4.2-7332-600.pdf
DIA-7332-001.pdf
HYD-7330-003.pdf
Tune up M4.2-7332-200.pdf
SP 3400
DIA-7334-001.pdf
Event codes M4.2-7334-600.pdf
Glossary M10-7334-001.pdf
HYD-7334-001.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-7334-001.pdf
Tune up M4.2-7334-400.pdf
SP3400 Four-Point Service.pdf
SP3400.pdf
SP 3500
Access M4.3-7335-001[1].pdf
M4.3-7335-001[1].pdf
SP 3500.operations.uk.pdf
ST3000
ST3000.pdf
SX3000
SX3000.pdf
TSP6000
TSP6000.pdf
WAV-50
1 PF11229-00C master service & parts.pdf
Lube and adj M1.0-2350-001.pdf
Lube and adj M1.0-2350-010.pdf
Settings M4.2-2350-210.pdf
Trouble codes 118 M4.2-2350-425[1].pdf
Trouble codes Wav-50 M4.2-2350-400.pdf
WAV-50-118 CROWN_DIA-2350-100.pdf
WAV-50- 84 DIA-2350-019.pdf
WAV50.pdf
WD2300S
WD2300S.pdf
WE_WS
MS-WE_WS2000.pdf
WE_WS2300.pdf
WE_WS2300 Service.pdf
WF3000
WF3000.pdf
WP
14245585-Crown_Wp2300s_Series_Forklift_Service_Repair_Manual.pdf.ppg28na.pdf
Crown_Wp2300s_Series_Forklift_Service_Repair_Manual.pdf.ppg28na.pdf
WP 2000
Controller operation M4.2-2720-001.pdf
DIA-2720-001.pdf
HYD-2720-001.pdf
Lube and adj M1.0-04.0-001.pdf
Lube and adj M1.0-2720-001.pdf
Troubleshooting M4.2-2720-400.pdf
Tune up M4.2-2720-200.pdf
WP charger settings PIB06-06-01.pdf
WP2000.pdf
WP2000S.pdf
WP 2300
Codes M4.2-2723-400.pdf
Controller operation M4.2-2720-001.pdf
DIA-2723-001.pdf
HYD-2720-001.pdf
Tune up M4.2-2723-200.pdf
Unigage M4.6-2720-100.pdf
WP charger settings PIB06-06-01.pdf
WP2300.pdf
WP2300S.pdf
ESR....2
ESR4000....3
ESR4000....3
TABLE OF CONTENT....4
M-IDX-2140-001....6
M-IDX-2140-002....7
M-IDX-2140-003....8
M-IDX-2140-004....9
SAFETY....10
Safety Symbols used in the Manual....12
General Maintenance and Repair Safety Notes....12
Maintenance and Repair....12
Before Leaving the Truck....13
Before Carrying out Work on the Truck....13
Before Operating the Truck....13
Warnings and Labels on the Truck....13
INTRODUCTION....14
General....16
Service Training....16
Operating Instructions....16
Service Training....16
Ordering Spare Parts....16
Using the Manual....16
Page Numbering in the Manual....17
Model-Number....18
LUBRICATION AND ADJUSTMENT....20
Jacking up the Truck....22
Raising the Truck with a Crane....23
Towing the Truck....23
Component Access....24
Removing the Floorboard....25
Seat Disassembly / Installation....25
Plastic Panel Disassembly / Assembly....25
Maintenance....27
Driver Participation....27
Daily Maintenance Log....27
Recommended Lubricants and Oils....27
Lubricants....27
Cold Store Trucks....27
Table Recommended Lubricants....28
Grease Items / Grease Intervals....29
Inspection and Maintenance Schedule....30
Battery Maintenance....30
Daily or 8 service hours....30
Inspection Points Pictures....31
Daily or 8 service hours (contd.)....32
Inspection Points Pictures (contd.)....33
Daily or 8 service hours (contd.)....34
Inspection Points Pictures (contd.)....35
3 Months or 250 hours....36
Inspection Points Pictures (contd.)....37
3 Months or 250 hours, part 2....38
Inspection Points Pictures (contd.)....39
3 Months or 250 hours, part 3....40
Inspection Points Pictures (contd.)....41
6 Months or every 500 hours....42
Inspection Points Pictures....43
Annually or every 1.000 hours....44
Inspection Points Pictures....45
Every 2 years or 2.000 hours....44
Inspection Points Pictures....45
Torques....46
Standard Screws and Nuts....47
Umbrako Screws and Nuts....47
HYDRAULICS....48
WARNING....50
Changing Hydraulic Oil....50
Hydraulic Pipes and Accessories....50
Filter....51
Tank....51
Drift Test....52
Drift Test Tilt Function....52
Drift Test Lift Function....52
Hydraulic System....54
No Demand for Steering SVT SVS SCV6 CV5....55
Description....56
Full Demand for Steering....57
Description....58
Low Speed Lift....59
Description....60
High Speed Lift....61
Description....62
Lower Circuit....63
Description....64
Reach Forward Circuit....65
Description....66
Tilt Down Circuit....67
Description....68
Tilt Back Circuit....69
Description....70
Sideshift Right Circuit....71
Description....72
Parking Brake Release Circuit....73
Description....74
Hydraulic Symbols....75
Valve Bank....79
Relief Valve #1 & #2 (RV1 & RV2)....79
Operation....79
Adjustment....79
RV1....79
RV2....79
Proportinal Valves PVA & PVH....80
DRIVE UNIT....82
General....84
Gear Unit Removal....84
Disassembly....84
Draining the oil....84
Steering Chain Removal....85
Drive Wheel Removal....85
Drive Motor....85
Maintenance....85
Bearing....85
Carbon Brushes....85
Commutator....85
Tools....86
Measurement Tools....87
Equipment....88
Equipment 2....89
Equipment 3....90
Gear Unit Maintenance....91
General....91
Gear Unit Main Components....91
Gear Unit Labelling....92
Setting Data....92
Disassembly....93
Gear Unit Cover Removal....93
Spur Bevel Gear and Wheel Shaft Removal....93
BEARING INNER RING REMOVAL....94
Wheel Shaft....94
Spur Bevel Gear....94
Wheel Bolt Removal....94
Pinion Shaft Disassembly....95
Extracting the Taper Bearing Inner Ring from the Pinion Shaft....95
Removing the Taper Bearing Cups from the Transmission Housing....95
Thread Protective Shield Removal....96
Pre-Assembly Test....96
Assembly....96
Pinion Shaft Installation Dimensions....96
l Press the bearing cup (2) into the bearing seat in Installing the Pinion Shaft Bearing Cup in the Housing....97
Bearing Inner Ring and Cup Installation....97
Inner Ring....97
Cup....97
Wheel Shaft Pre-Assembly....97
Wheel Bolt Assembly....97
Seal and Taper Bearing Assembly....98
Spur Bevel Gear Pre-Assembly....98
Pinion Shaft Pre-Assembly....98
Pinion Shaft Assembly....99
Pinion Shaft Pre-Assembly....99
Wheel Shaft Assembly....100
Spur Bevel Gear Play....101
Calculating the Torsional Flank Clearance....101
Adjusting the Bevel Wheel Set....101
Wheel Shaft Pre-Tension....102
Second Torsional Flank Clearance Check....102
Final Assembly....102
Thread Shield Assembly....102
Radial Shaft Packing Washer Assembly....103
Wheel Shaft Assembly....103
Housing Cover Assembly....103
Gear Upper Section Assembly....104
Live Ring Bearing Maintenance....104
Lubrication....104
Filling the Gear Unit with Oil....105
Gear Unit Assembly....105
ELECTRICS....106
ESR4000 Status Codes....117
ACCESS 1-2-3....117
Status Codes....117
When a Service Code Occurs....117
Truck does not Operate and there is no Status Code l HNS: Horn switch....117
Fault during power-up....117
The fault is not electrical....117
ACCESS 1-2-3 switches the truck off....117
Operating fault in an unmonitored input....117
Power Up Circuit Diagram....118
Maintenance....118
STATUS CODE 211to xxx....119
Electrics - General....108
Wire Colour Codes....108
Index of Abbreviations....109
Index of Abbreviations (contd.)....110
Electrical Symbols....111
Capacity Data Monitor....112
Capacity Data Monitor (on ACCESS 1 operator display)....112
Capacity Data Monitor (continued)....113
Capacity Data Monitor (continued)....114
Troubleshooting....115
Height Encoder ECR2....116
Troubleshooting....116
Access 1-2-3, Description....190
Access 1....190
Battery Discharge Indicator....191
Power "on"....191
Operator Improper Sequence Error....191
Service Required Light....191
Navigation Keys....192
Message Display....192
Capacity Data Monitor....192
Operator Menu....193
Operator Menu (cont.)....194
Service Menu....195
ANALYZER Menu....196
ANALYZER Menu (contd.), Inputs....197
ANALYZER Menu (Contd.), Inputs....198
ANALYZER Menu (Contd.), Outputs....199
ANALYZER Menu (Contd.), Test Outputs....200
CALIBRATION Menu....201
Accessing the CALIBRATION Menu l....203
CALIBRATION Menu (Contd.)....202
When to calibrate .....203
Calibration Procedures....203
Calibration Complete....203
Truck Calibration....204
FEATURES Menu....211
Drive Motor....235
Access....235
Maintenance....235
Pump Motor....235
Access....235
Maintenance....235
Emergency Disconnect Contactor....237
Contactor Tips....237
Contactor Coil Control....237
Replacing the Contactor Tips....237
Battery Maintenance....238
Charging the Battery....238
Replacing the Battery....238
Replacing the Battery with a Battery Trolley....241
BRAKE....242
Brake Systems, Description....244
Motor Brake System....244
Load Wheel Brake System....244
Bleeding the Brake System, general....244
Motor Brake....245
Operating Brake Adjustment....245
Parking Brake....246
Parking Brake Adjustment....246
System Bleeding....247
Brake Disassembly....247
Load Wheel Brake System....249
Load Wheel Brake Adjustment....249
System Bleeding....250
Load Wheel Brake Disassembly....251
STEERING....252
Steering, Function....254
Steering Unit Disassembly....255
Hydraulic Motor Disassembly....256
Steering Chain Adjustment....257
POT6 (Steer Angle Display) Replacement....258
Assembly and Adjustment....258
MAST....260
Torque Requirements....262
Fork Adjustments....262
Mast Testing (Assembled)....262
Flaking....262
Shock Absorbers....262
Mast Dampening Screws....262
ADJUSTMENT....262
Mast Disassembly....264
Mast Assembly....264
Mast Rollers....265
Mast Roller Adjustment....265
Mast Play Control....265
Fork Carriage....267
Before Disassembly....267
Disassembly....267
Fork Carriage Assembly....267
Fork Carriage Roller Adjustment....268
Lift Chains....269
General....269
INSPECTION....269
Cleaning....269
Wear....269
Freedom of Movement....270
Chain Tension....270
Chain Anchor and Pulleys....270
Worn or Missing Plates....270
Protruding or Turned Chain Pins....270
Corrosion....271
Chain Lateral Wear....271
Uneven Chain Tension....271
Misalignment of Lift Components....271
LIFT CHAIN LUBRICATION Dust will gather on oiled chains in dusty environments....272
Fork Tine Test....273
General....273
Fork Identification....273
Repairs....273
Crack Inspection....273
Fork Blade Warping....274
Verticality Test....274
Measuring the Fork Tip Width....275
Fork Tine Height Difference....275
Fork Stop....275
Wear....276
CYLINDERS....278
Maintenance....283
General....280
Inspection....283
Inspektion and repair of the parking brake cylinder....283
Installing the Piston Seal....284
Assembly of Small Rod Seals....284
Assembly of Large Rod Seals....284
Backup Ring Emergency Assembly....285
Cylinder Disassembly....285
Free-Lift Cylinder....285
Prior to Disassembly....285
Disassembly....285
Assembly....286
Lift Cylinder....287
Prior to Disassembly....287
Disassembly....287
Assembly....287
Reach Cylinder....287
Prior to Disassembly....287
Disassembly....287
Assembly....288
Sideshifter Cylinder....288
Prior to Disassembly....288
Disassembly....288
Assembly....288
Tilt Cylinder....288
Prior to Disassembly....288
Disassembly....288
Assembly....289
Parking Brake Cylinder....289
Prior to Disassembly....289
Disassembly....289
Assembly....290
ELECTRICAL DIAGRAMS....292
Control Circuit....294
Access1....295
Access2....296
Access3....297
Switches and Operator Controls....298
Switches and Operator Controls....299
Switches and Operator Controls....300
Mast, Hydraulic Components....301
Fuses, Fans and Contactors....302
Fuses, Fans and Contactors....303
Star Point Loom Connections....304
Star Point Loom Connections....305
Power Cables....306
HYDRAULIC SCHEMATIC....308
Hydraulic System....310
ESR4500....313
ESR4500 Series....313
TABLE OF CONTENTS....315
SAFETY....335
INTRODUCTION....339
LUBRICATION AND ADJUSTMENT....343
HYDRAULICS....361
DRIVE UNIT....387
ELECTRICS....395
BRAKE....641
STEERING....649
MAST....675
CYLINDERS....711
ELECTRICAL DIAGRAMS....731
HYDRAULIC SCHEMATIC....787
GPC....791
GPC2000....792
GPC2000....792
TABLE OF CONTENT....796
TABLE OF CONTENT 2....797
TABLE OF CONTENT 3....798
TABLE OF CONTENT 4....799
TABLE OF CONTENT 5 ....800
TABLE OF CONTENT 6....801
SAFETY....804
Safety Symbols used in the Manual....804
General Maintenance and Repair Safety Notes....804
Maintenance and Repair ....804
Before Leaving the Truck....805
Before Carrying out Work on the Truck....805
Before Operating the Truck....805
Warnings and Labels on the Truck....805
INTRODUCTION....808
General....808
Operating Instructions....808
Service Training....808
Ordering Spare Parts....808
Using the Manual....808
Model-Number....809
LUBRICATION AND ADJUSTMENT....812
Jacking up the Truck....812
Lifting the Truck with a Crane....812
Lifting the Truck with a second Truck....813
Towing the Truck....814
De-commissioning....815
Re-commissioning....815
Component Access....816
Models....818
Maintenance....819
Check and Maintenance Schedule....819
Daily or every 8 service hpurs (Part1)....819
Daily or every 8 service hpurs (Part2)....820
Monthly or every 100 service hours....821
Every 3 months or 250 service hours....823
Every 6 months or 500 service hours....823
Annually or every 1000 service hours....825
Every 2 years or 2000 service hours....825
Recommended Lubricants and Oils....828
Lubricants....828
Cold Store Trucks....828
Lubricant Type, Product, Manufacturer, Crown Part No., Type....828
Grease items and grease intervals....829
Torques....831
Screw grade marking. Nut grade marking....831
Standard Screws and Nuts....832
Standard Screws and Nuts....832
HYDRAULICS....836
Hydraulic Symbols....836
Hydraulic System....840
Operation....840
Platform Lift....841
Fork High Lift....842
Platform Lift and Fork High Lift....843
Hydraulic Unit Removal....844
Replacing the Hydraulic Pump....845
Removal....845
Installation....845
Pump motor....845
Replacing the Hydraulic Filter....845
Replacing the Suction Filter....845
Replacing the Oil....845
Start-Up....845
Checking the Valve Settings....847
Checking the Non-Return Valve....847
Checking the Safety Valve....847
Adjusting the Safety Valve....847
DRIVE UNIT....852
General....852
Environmental Protection....852
Drive Wheel....852
Removal....852
Assembly....852
Drive Unit Removal....853
Drive Unit Assembly....853
Transmission....853
Transmission Removal....853
Transmission Assembly....853
Transmission Repairs....854
Disassembly....854
Assembly....854
Bevel Wheel Set Adjustment....855
Oil Change....857
Live Ring Bearing....857
Removal....857
Assembly....857
ELECTRICS....862
Electrics - General....862
Wire Colour Codes....862
Abbreviations....863
Switch Symbol Abbrevation List....863
Sundry Abbrevations....864
Other Abbrevations....865
Electrical Symbols....865
Electrical Components....866
Transmitter (POT, FS, RS)....866
Brake Switch (BRS)....866
Lift/Lower switches (RAS, LOS)....866
Lift limiting switch (LMS)....866
Horn Switch (HNS)....866
Key Switch (KYS)....866
Emergency Disconnect (EDS)....866
Fuses (FU)....866
Walk along switch (WAS)....867
GPC2020....867
GPC2040....868
Programmer....869
General....869
Connection....869
Key Description....869
Display....869
SCROLL DISPLAY....869
CHANGE SETTING....869
MORE INFO....870
PROGRAM....871
TEST....871
DIAGNOSTIC....871
Key Combinations....871
SPECIAL DIAGNOSTIC mode....871
SPECIAL PROGRAM mode....872
Deleting the Error History....872
Copying (Cloning) Controller Settings....872
Resetting to Original Settings....872
Programmer Self-Test....872
Traction Controller Removal / Installation....873
Removal....873
Installation....873
Controller Test....874
Traction Controller 1207 and 1214 Settings....875
Controller Settings 1207 (GPC2020)....875
Controller Settings 1214 (GPC2040-2040S)....875
Program Menu....876
Menu TEST....877
Diagnostic and Special Diagnostic Menu....878
Fault Recovery (including recovery from disable)....879
Test Procedure....880
Pulse Monitor Trip - Test (PMT)....880
Equipment....880
Test Procedure....880
PMT- Test Wiring Diagram....881
1207 and 1214 Traction Controllers....882
General....882
Operating Features....882
Functions....883
Key Switch....883
Autotest (Watchdog, internal and external)....883
Current Limit....883
Overvoltage....883
Overtemperature....883
Performance Reduction at Low Voltage....883
Error Detection....883
Error Listing....884
Error Reset....884
Maintenance....885
1207 Control Line Connections....886
Power Line Connections....886
1214 Control Line Connections....887
Power Line Connections....887
1207 Control Panel....888
Setting Potentiometers....888
Programmer Connection....888
Status LED....888
Diagnostics with Status LED....888
CONNECTION SIDE OF CONTROLLER 1214....889
Programmer connector....889
Status LED....889
LED Diagnostics....889
Status LED....890
No. of Flashes, Display, Console Display, Explanation, Possible Cause....890
No. of Flashes, Display, Console Display, Explanation, Possible Cause....891
DACI-EL Steering Control System....893
Electrical Connections....893
Performance Connections....893
Control Section Connections....893
Steering Control System Error Codes....893
DACI-EL Steering Control System Error Codes....894
DACI-EL Steering Control System Error Codes (contd.)....897
Steering Control System Removal / Installation....897
Removal....897
Installation....897
Distributor Boards....899
General....899
Driver Board Usage....899
Board 804247-001....900
Board 804247-002....900
Board 804247-003....900
Jumper Arrangement and Usage....901
Jumper Settings....902
Platform Lift and Combination 804824....902
Electrical Steering Option....903
LED Signalling Board 808191....903
Board 808 191 Contact Arrangement....903
Board 808 197....905
Contactors....906
Important....906
Inspection....906
Contacts....906
Coils....906
Springs....906
GPC2020 Travel Contactor Repairs....906
Disassembly....906
Assembly....907
GPC2040 and GPC2040S Travel Contactor Repairs....908
Disassembly....908
Assembly....908
BRAKE....912
Operational Description....912
GPC 2020 Brake System....912
GPC 2040 Brake System....913
Removal....914
Preparation....914
Maintenance and Repairs....914
Installation....915
Air Gap Setting....915
Brake Moment Setting....916
Brake Test....917
Braking Distance Setting....917
GPC 2020 Standard 1.6 t....917
Braking Distance with Max. Load....917
Braking Distance with Truck Unladen....917
GPC 2040 Standard 2.0 t....917
Braking Distance with Max. Load....917
Braking Distance with Truck Unladen....917
GPC 2040 High Lift and Twin Lift 1.0 t....917
Braking Distance with Max. Load....917
Braking Distance with Truck Unladen....917
Testing the Load-Dependent Pressure Switch (GPC 2040 only)....918
STEERING....922
Steering Drive System....922
Steering Drive Removal....922
Repairing the Steering Drive....922
Removing the Motor from the Transmission....922
Replacing the Motor Bearings....922
Repairing the Steering Transmission....924
Tiller....927
Tiller and Recuperating Spring Removal (All Models)....927
Tiller and Recuperating Spring Assembly (All Models)....928
Tiller Adjustment....929
Forward Travel Setting for Mechanical Steering....929
Forward Travel Setting for Electrical Steering....930
Steering Chain....931
Chain Tension Adjustment....931
MAST....934
Lifting Mechanism....934
Lifting mechanism adjustment....934
Lift Stop Setting....935
Lift Chains....936
General....936
Inspection....936
Cleaning....936
Wear....936
Freedom of Movement....937
Chain Tension....937
Chain Anchor and Pulleys....937
Worn or Missing Plates....937
Protruding or Turned Chain Pins....937
Corrosion....938
Chain Lateral Wear....938
Uneven Chain Tension....938
Misalignment of Lift Components....938
Lift Chain Lubrication....939
Fork Tine Test....940
General....940
Fork Identification....940
Repairs....940
Crack Inspection....940
Fork Blade Warping....941
Verticality Test....941
Measuring the Fork Tip Width....942
Fork Tine Height Difference....942
Fork Stop....942
Wear....943
CYLINDER....946
General....949
Plunger Cylinders (single-acting)....946
Single-Acting Cylinder....948
Piston Cylinder (Double-Acting Cylinder)....947
Double-Acting Cylinder....948
General....949
Cylinder Removal....949
Replacing the Rod Seal....949
Platform Lift Cylinder....950
Free Lift Cylinder....951
Free Lift Cylinder for Platform Lift and Combination....952
DIAGRAMS....956
Control Circuit 2020....956
Driver Board 2020....957
Traction Controller 2020....958
Brake and BDI 2020....959
Tiller and Pedestrian Function 2020....960
Power Lead 2020....961
Overview 2040....962
Driver Board 2040....963
Driver Board 2040/Platform Lift....964
Traction Controller 2040....965
Brake and Brake Switch 2040....966
Lift/Lower and Limit Switch 2040....967
Tiller: BDI and Pedestrian Function 2040....968
Power Lead 2040....969
Overview 2040S....970
Steering Motor Controller 2040S....971
Steering Sensor Encoder 2040S....972
PCB Connection Lead 2040S....973
Steering Feedback POT 2040S....974
Backrest Control Cable 2040S....975
Tiller Lead 2040S....976
Tiller Head Cable 2040S....977
Power Lead 2040S....978
Power Lead 2040S Diagram....979
HYDRAULIC SCHEMATIC....982
2020/2040/2040S....982
Platform Lift....983
Fork Lift....984
Platform/ Fork Lift....985
GPC3000....986
GPC 3000 SERIES....986
Safety page serial no. cut Rev....990
Introduction page serial no. cut Rev....990
Lubrication & Adjustment page serial no. cut Rev....990
Hydraulic System page serial no. cut Rev....990
Drive Unit page serial no. cut Rev....991
Electrical System page serial no. cut Rev....991
Brake System page serial no. cut Rev....993
Steering page serial no. cut Rev....993
Lifting Mechanism page serial no. cut Rev....994
Cylinders page serial no. cut Rev....994
Schematic Diagrams page serial no. cut Rev....995
Hydraulic Schematic page serial no. cut Rev....996
Safety....998
Symbols and Indicators....1002
Safety Symbols....1002
General Symbols....1002
Fork direction....1002
General Text Indicators....1002
General Safety Instructions....1003
Maintenance and Repair Instructions....1003
Maintenance and Repair....1003
Before Parking the Truck....1003
Before Working on the Truck....1003
Before Starting the Truck....1003
Warning and Instruction Decals on the Truck....1003
Introduction....1006
General....1008
Service training....1008
Replacement Parts....1008
Subsequent Attachments and Modifications....1008
Using the Manual....1008
Contact Address....1008
Models....1009
Lubrication & Adjustment....1010
Lifting and Jacking....1012
Lifting the Truck....1012
Lifting the truck with a crane....1012
Lifting the truck with a forklift truck....1013
Towing the truck....1013
Towing the truck....1013
Jacking up the truck....1014
Jacking up the truck....1014
Taking the Truck out of Service....1015
Testing Re-Commissioned Trucks....1015
Restoring the Truck to Service....1015
Recommended Lubricants and Accessories....1016
Cold Store Trucks....1016
Routine Maintenance....1018
GPC 3020/40/60 Inspection and Lubrication Points....1022
GPC 3045 Inspection and Lubrication Points....1024
GPC 3055 Inspection and Lubrication Points....1026
Torques....1028
Standard Torques....1028
Hydraulic System....1030
General....1032
Hydraulic Lines and Ports....1032
Bleeding the hydraulic system....1032
Drift Test....1032
Oil Change....1032
Capacity....1032
Relief Valves....1033
Replacing relief valves....1034
Testing and adjusting the relief valves....1034
RV1 test....1034
RV2 test....1034
Adjusting RV1/RV2....1034
Hydraulic Unit....1035
Hydraulic unit removal....1035
Hydraulic unit assembly....1035
1.2 kW hydraulic unit disassembly....1035
Dismantling....1035
Assembly....1036
Start Up Procedure....1036
2.2 kW hydraulic unit disassembly....1038
Dismantling....1038
Bleeding and Flushing the System....1041
Before flushing and bleeding the system....1041
Bleeding....1041
Flushing....1041
Drift Test....1041
Drive Unit....1044
Changing the Transmission Oil....1046
Components....1048
Replacing the shaft seal of the driven shaft....1049
Special Tools Required....1050
Preparation....1050
Shaft Seal Removal....1050
Removing the driven shaft....1050
Driven shaft assembly....1050
Adjusting the driven shaft friction torque....1050
Drive Wheel and Wheel Bolts....1052
Drive Wheel Disassembly....1052
Drive Wheel Assembly....1052
Replacing the Wheel Bolts....1052
Replacing the Drive Unit....1053
Special Tools Required....1053
Removal....1053
Assembly....1053
Drive Transmission Unit....1054
Repairing the Drive Transmission Unit....1055
Preparation....1055
Dismantling....1055
Driven shaft removal....1055
Bevel gear and bevel pinion removal....1055
Assembly....1056
Bevel pinion and drive pinion....1056
Bevel gear....1057
Electrical System....1060
General....1062
Wire colour code....1062
Contact Symbol Abbreviations....1063
Electrical Symbols....1065
Components....1067
GPC 3020/40/60 without Platform Lift....1067
GPC 3040/60 with Platform Lift....1070
GPC 3045 with Platform Lift....1074
GPC 3055....1077
Operator Menu....1080
Operator Menu....1081
Service Menu....1082
Analyzer....1082
Analyzer....1083
Access 2 Input....1085
Access 3 Input....1086
Access 5 Input....1087
Test Output....1088
Calibration....1089
Calibration....1090
Features....1091
Features....1092
Features....1093
Features....1094
Hours....1095
Events....1096
Performance....1097
Performance....1098
Performance....1099
Performance....1100
Performance....1101
Utilities....1102
Parameter Setting....1103
Parameter Setting for the GPC 3020....1103
Parameter Setting for all Trucks except the GPC 3020....1104
Control Modules....1107
General....1107
Power Fuses....1107
Servicing and Replacing the Control Modules....1108
Discharging the Capacitors....1108
Servicing the Control Modules....1108
Replacing Control Modules....1108
Removal....1108
Assembly....1108
Event Codes....1109
Access 2....1109
Event Codes....1113
Access 3....1113
Event Codes....1121
Access 5....1121
Drive Motor....1129
Drive Motor Disassembly....1129
Drive Motor Assembly....1129
Repairing the Drive Motor....1130
Preparation....1130
Dismantling the Rotor Assembly....1130
Assembling the Rotor Assembly....1130
Final task:....1130
Steer Motor....1131
Special Tools Required....1132
Steer Motor Disassembly....1132
Steer Motor Assembly....1132
Repairing the Steer Motor....1132
Preparation....1132
Steer Motor Disassembly....1132
Steer Motor Assembly....1132
Final task:....1132
Pump Motor....1133
General Maintenance Instructions....1133
Maintenance Instructions....1133
1.2 kW Pump Motor....1133
Brushes....1133
Armature....1134
2.2 kW Pump Motor....1134
Brushes....1134
Armature....1134
Battery....1135
General....1135
Charging the Battery....1135
Replacing the Battery....1135
Contactors....1136
Inspection....1136
Contacts....1136
Coils....1136
Springs....1136
Servicing....1137
Dismantling....1137
Assembly....1137
Controller Safety Test (PMT)....1138
General....1138
Required tools....1138
Carrying out the PMT....1138
General....1138
Testing Access 3....1138
General....1138
Performing the test....1138
Testing Access 5....1139
General....1139
Brake System....1140
Electromechanical Brake....1142
General....1142
Servicing the Brake....1142
Measuring the air gap....1142
Replacing the Brake....1143
Installing a wear part kit....1143
Remove and disassemble the brake....1143
Replacing wear parts....1143
Brake re-assembly....1144
Replacing the brake in full....1145
Removal....1145
Assembly....1145
Steering....1148
Steering Assembly....1150
Steering Assembly Components....1151
Steering Assembly Removal....1151
Steering Assembly Installation....1151
Final tasks:....1151
Repairing the Steering Transmission....1152
Preparation....1152
Dismantling....1152
Assembly....1152
Final tasks:....1153
Lifting Mechanism....1154
GPC 3020/40/60 Fork Height....1156
General....1156
Adjusting the Height of the Lowered Forks....1156
Lift Chains....1158
Inspection....1158
Cleaning Methods....1158
Wear....1158
Freedom of Movement of Chain Links....1160
Chain tension....1160
Chain Anchor and Pulleys....1161
Worn Connection Plates....1161
Protruding or Turned Chain Pins....1161
Corrosion....1162
Side wear....1162
Uneven chain tension....1162
Misaligned Lift Components....1162
Lift Chain Lubrication....1163
General....1163
Lubrication Intervals....1164
Lubrication....1164
Separating Lift Chains....1165
Tools and Equipment Required....1165
Forks....1166
General....1166
Repairs....1166
Checking the Forks....1166
Crack Inspection....1166
Cylinders....1168
General....1170
Safety....1170
For your personal protection....1170
Hydraulic System Repair Instructions....1170
Tools....1171
Producing extractors....1171
Protective mechanisms....1171
Gasket Assembly....1172
Old Gasket Removal....1172
Large Gasket Assembly....1172
Tools required....1172
Assembly....1172
Small Gasket Assembly....1173
Tools required....1173
Assembly....1173
Rod Seal Assembly, Sealing Lip First....1174
Servicing....1175
General....1175
Cylinder Disassembly....1175
Replacing the Rod Seals....1175
Schematic Diagrams....1178
Overview....1180
With Key Switch and Keypad....1181
TCM - Combi AC1 Power Side....1182
TCM - Combi AC1 Logic Side....1183
SCM - EPS AC0 Logic Side....1184
Interface #1 Tiller....1185
Interface #2 Backrest....1186
GPC3045, 3055 Connections....1188
Switch Connection....1189
Handle Circuit....1191
Display with Options....1192
CAN Connection....1194
Power Cables GPC 3000....1195
Harness, Walk Beside Switch....1196
GPC3055....1196
Tables for Fig. 818598_2G_1 (see page 199)....1197
Connector housing....1197
Contact pins....1197
Wire connections....1197
Beside Switch Assy....1198
GPC3055 (no PPC)....1198
Connector housing....1198
CAN Interface Bridge....1199
GPC3055....1199
Connector housing....1199
Lift / Lower Scissors Harness....1200
GPC3040 / 3060, GPC3045....1200
Connector housing....1200
Scissors RAS - LOS Assy....1201
GPC3055 (no PPC)....1201
Connector housing....1201
Walk Beside Switch Harness F/C....1202
Tables for Fig. 820541_2B_1 (see page 205)....1203
Connector housing....1203
Contact pins....1203
Wire connections....1203
Microswitch Assy....1204
Connector housing....1204
Contact pins....1204
Horn Harness....1205
Connector housing....1205
Contact pins....1205
Horn Switch Assembly....1206
SAS Switch Assembly....1207
Main Harness GPC 3000....1208
Tables for Fig. 818240-1_2Q (see page 211)....1209
Connector housing....1209
Cable lugs....1209
Contact pins....1210
Wire connections....1210
X10 Handle Harness....1212
Connector housing....1212
Contact pins....1212
Wire connections....1213
Display Harness GPC 3000....1214
Tables for Fig. 818597_2L_1 (see page 217)....1215
Contact pins....1215
Connector housing....1215
Wire connections....1215
Adapter ZAPI Console....1216
Contact pins....1216
Connector housing....1216
BRK Switch Assembly....1217
X10 - Handle....1217
Contact pins....1217
GPC 3000 Standard....1218
CAN-Tiller Harness Assembly....1218
Contact pins....1218
Connector housing....1218
GPC Standard 3000....1219
Steer Sensor Assembly....1219
Contact pins....1219
Connector housing....1219
Walk Beside Switch Assy....1220
Contact pins....1220
Connector housing....1220
Platform Lift Harness....1221
Contact pins....1222
Connector housing....1222
Wire connections....1222
Backrest Harness #2 Platform Lift....1223
Contact pins....1223
Connector housing....1223
Straight Ahead Sensor Assy....1224
Contact pins....1224
Connector housing....1224
CAN Interface Bridge....1225
Contact pins....1225
Connector housing....1225
Lift Lower Scissors Harness GPC 3000....1226
Contact pins....1226
Connector housing....1226
LMS Harness Scissors Lift....1227
Contact pins....1227
Scissors RAS - LOS Assy GPC 3000....1228
Connector housing....1228
Platform Lift Fork Switch Assembly RAS / LOS 2-5....1229
Connector housing....1229
Backrest Harness #2 Platform / Forks....1230
Contact pins....1230
Connector housing....1230
Battery Latch Switch (BLS) Assy....1231
Contact pins....1231
Connector housing....1231
Adapter Key Switch....1232
Contact pins....1232
Walk Beside Switch Harness F/C....1233
Contact pins....1233
Connector housing....1233
Wire connections....1234
Heater Assembly....1235
Order number 820639-001....1235
Order number 820639-002....1235
Order Numbers 820639-001 & 820639-002....1235
Connection Cable Alarm....1236
Contact pins....1236
Connector housing....1236
Connection Cable DC / DC Converter....1237
Contact pins....1237
Connector housing....1237
DC / DC Converter....1238
Contact pins....1238
Connector housing....1238
Hydraulic Schematic....1240
GPC 3020....1242
GPC 3040/3045/3060 without Platform, GPC 3055....1243
GPC 3040/3045/3060 with Platform....1244
GPW....1246
DIA-17.1-005....1247
Early DIA-17.0-004....1251
MS-GPW1000....1252
GPW1000....1252
Englisch....1252
INDEX....1257
IDX -1710 -002....1258
IDX -1710 -003....1259
GENERAL MAINTENANCE ADVICE....1264
SAFETY INSTRUCTIONS....1264
Maintenance....1267
LUBRICATION AND SETTING....1267
TRUCK JACKED UP....1267
Lubricants....1268
With cold store trucks -Schmieröl....1268
LUBBRICANTS AND OIL RECOMMENDATIONS....1269
CHECK AND MAINTENANCE PLAN....1270
Daily Maintenance Check....1270
DAILY OR AFTER 8 HOURS OF OPERATION....1271
Check Points....1272
MONTHLY OR EVERY 100 HOURS OF OPERATION....1273
Check Points....1274
QUARTERLY OR EVERY 250 HOURS OF OPERATION....1275
Check Points....1276
SIX MONTHLY OF EVERY 2000 HOURS OF OPERATION....1277
Check Points....1278
OIL and Grease Lubrication Points....1279
Drawing Lubrication Points....1280
ELECTRICAL SYSTEM....1281
Electric Parts Layout....1283
WIRING COLOUR CODE....1284
Index of Abbreviations....1285
Other Abbreviations....1286
ELETRICAL SYMBOLS....1287
Controller (1207-1115)....1288
Functions....1289
Emergency reverse....1289
Acceleration/deceleration rate....1289
Brake....1289
Throttle....1289
Throttle response....1289
Fault recording....1290
Fault detection....1290
Plug braking....1291
Creep speed at first throttle....1291
Low speed....1291
MOSFET....1292
Pulse with modulation (PWM)....1292
Ramp start (anti roll-back)....1292
Key switch....1292
Quick start....1292
Watchdog (external, internal)....1292
Current limiting....1293
Overvoltage cutoff....1293
Overtemperatur....1293
Undervoltage cutback....1293
Pilot wire pins....1294
Power cable connections....1294
Adjustment panel....1295
Manually adjustable potentiometer....1295
Programmer connector....1295
Status LED....1295
LED Diagnostics....1295
LED CODES....1296
Maintenance....1298
SAFETY....1298
Cleaning of the controller....1298
Removal of controller....1299
Installation of controller....1299
Controler check....1300
Trouble shooting chart....1303
Fault recovery (including recovery from disable)....1305
Programmer....1306
Connections....1306
Keys....1307
Display....1308
SCROLL DISPLAY ARROWS....1308
CHANGE VALUE ARROWS....1309
MORE INFO KEY....1309
Operating Modes....1309
PROGRAM MODE....1310
TEST MODE....1311
DIAGNOSTIC MODE....1311
SPECIAL PROGRAM MODE....1311
Controller cloning....1312
SPECIAL DIAGNOSTIC MODE....1312
Peace-of-Mind Programming....1313
Programmer Self Test....1313
PROGRAM MENU....1314
TESTMENU....1315
Table 3 Diagnostic and Special Dianostic „Menu“....1316
SPECIAL PROGRAM MENU....1317
Settings....1318
BRAKE....1319
General....1319
Drive wheel Brakes....1319
Removal....1319
Installation....1320
Setting up Air Gap....1321
Setting up brake torque....1321
Carrying out Brake Test....1321
Lifting Mechanism....1322
Setting up....1322
Setting up Fork Height....1323
Electrical Diagrams....1324
Schematic with Options....1324
Distribution Panel....1325
Handle and Brake Circuit....1326
Traction Controller Circuit....1327
Power Cables Connections....1328
Main Wiring Harness....1329
Control Handel Cable....1330
Control Handel Cable....1331
Main Cotrol Handel Harness....1332
ORS - BRS - BR Harness....1333
ORS - BRS - BR....1334
HYDRAULIK SCHEMATIC....1335
TOOLS / CONNECTORS....1336
LP....1339
LP3010_3020....1340
LP3010/3020....1340
REVISION....1342
Overview of Revisions....1342
TABLE OF CONTENT....1346
TABLE OF CONTENT 2....1347
TABLE OF CONTENT 3....1348
TABLE OF CONTENT 4....1349
TABLE OF CONTENT 5....1350
TABLE OF CONTENT 6....1351
TABLE OF CONTENT 7....1352
SAFETY....1356
Safety Symbols used in the Manual....1356
General Maintenance and Repair Safety Notes....1356
Maintenance and Repair....1356
Before Leaving the Truck....1357
Before Carrying out Work on the Truck....1357
Before Operating the Truck....1357
Warnings and Labels on the Truck....1357
INTRODUCTION....1360
General....1360
Operating Instructions....1360
Service Training....1360
Ordering Spare Parts....1360
Using the Manual....1360
Model-Number....1361
LUBRICATION AND ADJUSTMENT....1364
Jacking up the Truck....1364
Lifting the Vehicle with a Crane....1365
Lifting the Vehicle with a Fork-Lift Truck....1365
Towing the vehicle away....1365
Access to Components....1366
LP3010 Overview....1366
LP3020 Overview....1367
LP 3010 Overview – High Version....1368
LP 3020 Overview – High Version....1369
Main components under the motor panel....1370
Access to Drive Unit, Hydraulic System and Electrical Components DANGER!....1371
Maintenance....1372
Operator Involvement....1372
Daily Maintenance Record....1372
Inspection and Maintenance Schedule....1372
Daily or Every 8 Operating Hours, Part 1....1373
Daily or Every 8 Operating Hours, Part 2....1374
Monthly or Every 100 Operating Hours....1375
Monthly or Every 100 Operating Hours, Page2....1376
Scheduled Replacement of High Pressure Hoses....1375
Every 3 Months or 250 Operating Hours....1377
Every 3 Months or 250 Operating Hours....1378
Every 6 Months or 500 Operating Hours....1379
Every 6 Months or 500 Operating Hours....1380
Anually or Every 1000 Operating Hours....1381
Annually or Every 1,000 Operating Hours....1382
Recommended Lubricants....1384
Lubricants....1384
Lubrication points / intervals....1385
Lubrication Points, Overview....1386
Torques....1387
Standard Srews and Nuts....1387
HYDRAULICS....1390
Changing Hydraulic Oil....1390
Hydraulic Pipes and Accessories....1390
Removing the Hydraulic Unit....1391
Replacing the Hydraulic Pump....1392
Removal....1392
Installation....1392
Commissioning....1392
Pump Motor....1393
Replacing the Hydraulic Filter....1393
Oil Change....1394
Valve Block....1395
Pressure Relief Valves....1395
Operation....1395
Platform Lift Pressure Relief Valve Setting....1395
Aux. Lift Pressure Relief Valve Setting....1396
Non-Return Valve....1396
Functional Test....1396
Compensation Valve....1396
Functional Test....1396
Line Break Safety Device....1397
Tools Required....1397
Line Break Safety Device Functional Test ....1397
Emergency Lowering Valve....1398
Tools Required....1398
Emergency Lowering Valve Functional Test....1398
DRIVE UNIT....1402
Preparation....1402
Material Required....1402
Drive Unit Removal....1402
Gear Unit Repair....1404
General....1404
Drive Unit Removal....1404
Gear Unit Assembly....1406
Installing the Drive Unit....1407
ELECTRICS....1410
Electrical Components....1410
AV Alarm....1410
CX Horn....1410
F1, F2, FA, FA4 Fuses....1410
F3, FA3 Fuses....1410
F01 Aisle Recognition Sensor....1410
F02 Aisle Recognition Sensor....1410
FE Brake....1410
HN3 Alarm....1410
K1, K2 Travel Direction Contactors....1410
K4 Main Contactor....1410
K6 Steering Contactor....1411
M1 Traction Motor....1411
M2 Pump Motor....1411
M3 Steering Motor....1411
MAC Chain Slack Switch....1411
MBC....1411
MF Steering Limit Switch....1411
MFC Lift Limit Switch (Cabin)....1411
MFF Lift Limit Switch (Forks)....1411
MFT Overhead Guard Monitor....1411
MLS Lift Interruption Switch....1411
MMI, MMA, PT Transmitter....1411
MPR Door Switch....1412
MP1, MP3 Pallet Recognition Switch....1412
MR Lower Brake Switch....1412
MS1, MS2 Steering: Tachogenerator....1412
MSC, MDC, PTP Cabin Lift / Lower....1412
MV2, MV3 Lift Height Dependent Speed Reduction....1412
PE Emergency Disconnect Switch....1412
PCE, PCEglf Brake Switch....1413
PCS, PCD Fork Lift / Lower....1413
PCS, PCSD, MCSDead Man Switch....1413
PCT, MCT Aisle Guidance Two-Hand Switch....1413
PCX, PCXglf Horn Switch....1413
PEA Chain Slack Bypass Switch....1413
PFA Work Lights Switch....1413
PLS Bypass Switch....1413
PS Pressure Switch....1413
PTR Steering Angle Potentiometer....1414
QC Key Switch....1414
RL1 Trip Relay....1414
MK3N Traction Controller....1415
General....1415
Precautionary Measures....1415
Maintenance....1415
Replacing the Traction Controller....1415
Settings after Replacing the Traction Controller....1416
MK3N Lift Controller....1417
General....1417
Precautionary Measures....1417
Maintenance....1417
Replacing the Lift Controller....1417
Settings after Replacing the Lift Controller....1418
EPS-DC Steering Controller....1419
General....1419
Precautionary Measures....1419
Maintenance....1419
Replacing the Traction Controller....1419
Settings after Replacing the Steering Controller....1420
Replacing Fuses....1420
Graphic Display....1421
General....1421
Precautionary Measures....1421
Maintenance....1421
Replacing the Graphic Display....1422
Settings after Replacing the Graphic Display....1422
Programmer....1424
General....1424
Connecting the programmer and the adapter....1425
Data Connection to the Pump Controller:....1425
Data connection to the Traction Controller:....1425
Data Connection to the Graphical Display....1426
Description of Keys....1427
Operating Menu....1427
General....1427
Menu Functions....1427
Graphic Display, Menu Structure....1428
Graphic Display ....1429
Parameter Change Menu....1429
Maximum Speed Setting....1430
TESTER Menu....1431
TESTER Menu....1431
TESTER Menu, Continued....1432
SAVE PARAMETER Menu....1432
ALARMS Menu....1433
ALARMS Menu....1433
ALARMS Menu, Continued....1434
ALARMS Menu, Continued2....1435
ALARMS Menu, Continued 3....1436
Lanuage Reference List for the ALARM Menu....1437
SET OPTIONS Menu....1438
ADJUSTMENTS Menu....1439
Traction Control System, Menu Structure....1440
Traction Control System....1441
PARAMETER CHANGE Menu....1441
TESTER Menu....1442
ALARMS Menu....1443
ALARMS Menu, Continued....1444
SET MODEL Menu....1444
Lift Control System....1446
Menu Structure....1445
PARAMETER CHANGE Menu....1446
TESTER Menu....1447
ALARMS Menu....1448
Steering Control System....1449
Menu Structure....1449
PARAMETER CHANGE Menu....1450
TESTER menu....1451
SET OPTIONS menu....1452
ADJUSTMENTS menu....1453
ALARM....1454
Audible Alarm....1454
Programmer, ALARMS menu....1454
ALARMS menu....1454
Remot Control for Platform....1455
Traction Control System Safety Test....1456
Electric Motors....1458
General Maintenance Instructions....1458
Preparation....1458
Important Maintenance Instructions....1458
Drive Motor Maintenance....1459
Access to Brushes....1459
Maintenance....1459
Armature....1459
Bearings....1459
Pump Motor Maintenance....1460
Access to Brushes....1460
Maintenance....1460
Armature....1460
Bearings....1460
Steering Motor Maintenance....1461
Access to Brushes....1461
Maintenance....1461
Battery....1462
General....1462
Operation....1462
Replacing the Battery....1462
BRAKE....1466
General Functional Description....1466
Removal....1466
Assembly....1467
Air Gap Setting....1467
Brake Moment Setting....1467
Brake Test....1467
Braking Distances Series LP....1468
STEERING....1472
Operation....1472
Steering Chain Adjustment....1472
Steering Pod Removal / Installation....1473
Steering Motor Removal / Assembly....1473
Steering Transmission Removal / Assembly....1474
Potentiometer (PTR) Installation....1475
Functional Test....1475
Steering Limit Switch (MF)....1475
Replacing the Steering Limit Switches....1475
Limit Switch Test....1476
Limit Switch Adjustment....1476
MAST....1480
Torques....1480
Fork Settings....1480
Mast Control (Fitted)....1480
Flaking....1480
Mast Stop Buffer....1480
Fork Carriage Stop Screws....1480
Removing the Platform without Aux. Lift (1200 mm lift height)....1481
Removing the Platform with Aux. Lift (1200 mm lift height)....1483
Removing Platform without Aux. Lift (1800 mm lift height)....1486
Removing Platform with Aux. Lift (1800 mm lift height)....1489
Mast Rollers....1492
Removing the Mast Rollers....1492
Fitting the Mast Rollers....1492
Guide Rollers....1492
Guide Roller Removal....1492
Guide Roller Installation....1493
Platform Installation (all variants)....1494
Fork Carriage (Aux. Lift Only)....1495
Fork Carriage Removal....1495
Removing the Fork Carriage Rollers....1496
Fork Carriage Roller Installation....1496
Fork Carriage Installation....1497
Tensioning the Lift Chain....1497
Lift Chains....1499
General....1499
INSPECTION....1499
Cleaning....1499
Wear....1499
Freedom of Movement....1500
Chain Anchor and Pulleys....1500
Worn or Missing Plates....1500
Protruding or Turned Chain Pins....1500
Corrosion....1501
Chain Lateral Wear....1501
Misalignment of Lift Components....1501
LIFT CHAIN LUBRICATION....1502
Fork Tine Test....1503
General....1503
Fork Identification....1503
Repairs....1503
Crack Inspection....1503
Fork Blade Warping....1504
Verticality Test....1504
Measuring the Fork Tip Width....1505
Fork Tine Height Difference....1505
Fork Stop....1505
Wear....1506
CYLINDER....1510
Cylinders....1510
General....1510
Plunger Cylinders (single-acting)....1510
Single-Acting Cylinder....1512
Piston Cylinder (Double-Acting Cylinder)....1511
Double-Acting Cylinder....1512
Maintenance....1513
Inspection....1513
Seal Installation....1514
General....1514
Aux. Lift Cylinder....1514
Removal - Preparation....1514
Aux. Lift Cylinder Removal....1514
Repairing the Aux. Lift Cylinder....1515
Disassembly....1515
Inspection....1515
Assembly....1516
Aux. Lift Cylinder Assembly....1516
Lift Cylinder....1516
Removal - Preparation....1516
Lift Cylinder Removal....1517
Repairing the Lift Cylinder....1517
Disassembly....1517
Inspection....1518
Assembly....1518
Lift Cylinder Assembly....1518
DIAGRAMS....1522
Electrical Circuit....1522
HYDRAULIC SCHEMATIC....1526
Hydraulic System....1526
Operation....1526
LP3010, 1025 mm lift height, without aux. lift....1527
LP3020, 1845 mm lift height, with aux. lift....1528
LP3010, 1620 mm lift height, without aux. lift....1529
LP3020, 2440 mm lift height, with aux. lift....1530
PW3500....1532
Resistor DIA-6435-200....1533
Transistor DIA-6435-200....1541
RR....1561
TSB0391....1562
TSB0407....1563
TSB0426....1564
RT....1566
MS-RT3010....1567
RT3010....1567
TABLE OF CONTENT....1568
M-IDX-2800-001....1570
M-IDX-2800-002....1571
M-IDX-2800-003....1572
M-IDX-2800-004....1573
SAFETY....1574
Safety Symbols used in the Manual ....1576
General Maintenance and Repair Safety Notes....1576
Maintenance and Repair....1576
Before Leaving the Truck....1577
Before Carrying out Work on the Truck....1577
Before Operating the Truck....1577
Warnings and Labels on the Truck....1577
INTRODUCTION....1578
General....1580
Operating Instructions....1580
Service Training....1580
Ordering Spare Parts....1580
Using the Manual....1580
Page Numbering in the Manual....1581
Model-Number....1582
LUBRICATION AND ADJUSTMENT....1584
Jacking up the Truck....1586
Raising the Truck with a Crane....1587
Towing the Truck....1587
Component Access....1588
Component Access Part 2....1589
Removing the Floorboard....1590
Removing the Side Panel....1590
Access to Drive Unit, Hydraulic System and Electrical Components....1590
Maintenance....1591
Driver Participation....1591
Daily Maintenance Log....1591
Recommended Lubricants and Oils....1591
Lubricant Type....1592
Grease Points, Overview....1593
Grease Points / Intervals....1594
Inspection and Maintenance Schedule....1594
Battery Maintenance....1594
Daily or every 8 service hours....1595
Picture....1596
Monthly or every 100 service hours....1597
Picture....1598
Every three months or 250 service hours....1599
Picture....1600
Every six month or 500 service hours....1601
Picture....1602
Annually or every 1000 service hours....1603
Every 2 years or 2000 service hours....1603
Picture....1604
Caster....1605
Torques....1606
Table....1606
HYDRAULICS....1608
Hydraulic System....1610
Operation....1610
Electric Diagram....1610
Removing the Hydraulic Unit....1611
Picture....1611
Replacing the Hydraulic Pump....1612
Disassembly....1612
Assembly....1612
Start-up....1612
Replacing the Hydraulic Filter....1612
Replacing the Suction Filter....1612
Oil Change....1613
Drawing Overview....1614
Valve Setting Control....1615
Non-return valve control....1615
Safety Valve Control....1615
Safety Valve Setting....1615
Drawing Overview....1616
DRIVE UNIT....1618
Drive Unit....1620
Preparation....1620
Removal....1620
Maintenance....1621
Drive Unit Disassembly....1622
Assembly....1622
Adjusting the Bevel Wheel Set....1623
Final Assembly....1623
Drive Unit Re-Installation....1624
Live Ring Bearing Replacement....1624
Forcing out the Live Ring Bearing....1624
Pressing in the Live Ring Bearing....1625
Installation of the Live Ring Bearing in the Drive Unit....1625
ELECTRICS....1626
Electrical Components....1628
Transmitter (MMI,MMA,PT)....1628
Fast / Slow Switch (HES)....1628
Safety Pedal (PCT)....1628
Lift / Lower Switch (PCS, PCD)....1628
Lift Limit Switch (MFF)....1628
Pressure Switch (PS)....1628
Horn Switch (PCX)....1628
Horn (CX)....1628
Key Switch (QC)....1628
Seat Height Adjustment Switch (PSDS)....1628
Steering Angle-Dependent Speed Reduction Microswitch....1628
Seat Height Adjustment Limit Switch (MF)....1629
Fans (VNT)....1629
Brake (FE)....1629
Emergency Disconnect Switch (PE)....1629
Fuses (F1, F2, FA)....1629
Traction Motor (M1)....1629
Pump Motor (M2)....1629
Pump Contactor (K3)....1629
Main Contactor (K4)....1629
Steering Motor (M3)....1629
Encoder (MS)....1629
Limit Switch (MF)....1629
Contactor (K6)....1629
Fuses (F3, FA3)....1629
Picture....1630
Picture....1631
ES1 Traction Controller....1632
General....1632
Precautionary Measures....1632
Operational Features....1632
Speed Control....1632
Reduced Speed Range....1632
Downhill Speed Control....1632
Regenerative Braking....1632
Anti - Roll Down Function....1632
Hourmeter....1633
Self Test....1633
Monitored Circuits....1633
Protective Devices....1634
Polarity Protection....1634
Wiring Errors....1634
Temperature....1634
Start Sequence....1634
Safety Class....1634
Maintenance....1634
ES1 Traction Controller Connections....1635
Programmer....1636
Description of Keys....1637
Operating Menu ES1 Controller....1637
General....1637
Menu Functions....1637
Operating Menu - Overview....1638
PARAMETER CHANGE Menu....1639
Max. Speed Setting....1640
Speed Measurement....1641
TESTER Menu....1642
ALARMS Menu....1643
Error Code Display in SAM Hourmeter....1643
ALARMS Menu Table....1644
PROGRAM VACC Menu....1646
CONFIG Menu....1647
SAM Hourmeter....1648
Traction Controller Replacement and Trans-fer of Service Hours into the new Controller....1648
Traction Controller Safety Test....1649
Diagram....1649
Battery....1650
General....1650
Operation....1650
Battery Replacement....1650
Battery Removal....1650
Replacing the Battery with a Crane....1651
Replacing the Battery with a Trolley....1652
Charging the Battery....1653
Electric Motors....1654
General Maintenance Instructions....1654
Preparation....1654
Important Maintenance Instructions....1654
Electric Motors....1654
General Maintenance Instructions....1654
Preparation....1654
Important Maintenance Instructions....1654
Traction Motor Maintenance....1655
Access to the Brushes....1655
Maintenance....1655
Armature....1655
Bearings....1655
Pump Motor Maintenance....1656
Access to the Brushes....1656
Maintenance....1656
(OPTION) Steering Motor Maintenance....1657
Access to the Brushes....1657
Maintenance....1657
Seat Variable Displacement Motor Adjustment....1657
BRAKE....1658
Brake....1660
General Functional Description....1660
Removal....1660
Assembly....1661
Air Gap Setting....1661
Brake Moment Setting....1661
Brake Test....1662
RT3010 Nominal Braking Distances and Screw Depth....1662
STEERING....1664
Steering....1666
Operation....1666
Diagram....1666
Adjusting the Upper Steering Chains Adjusting the Lower Steering Chain....1667
Adjusting the Lower Steering Chain....1667
Checking the Sliding Clutch....1668
Replacing the Sliding Clutch....1668
Steering Sensor Removal / Installation....1669
Steering Motor Removal / Installation....1669
Limit Switch Removal / Installation....1669
Diagram....1670
LIFTING MECHANISM....1672
Lifting Mechanism....1674
Test....1674
Adjusting the Stop....1674
Diagram....1675
CYLINDERS....1676
Cylinders....1678
General....1678
Plunger Cylinders (single-acting)....1678
Piston Cylinder (Double-Acting Cylinder)....1679
Single-Acting Cylinder....1680
Double-Acting Cylinder....1680
Maintenance....1681
Inspection....1681
Seal Installation....1682
General....1682
Lift Cylinder....1682
Removal Preparation....1682
Removal....1682
Repairing the Lift Cylinder....1683
Disassembly....1683
Inspection....1683
Assembly....1683
Gas Pressure Spring Removal and Assembly....1684
Removal Preparation....1684
Removal....1684
Assembly....1684
ELECTRICAL DIAGRAMS....1686
Control Circut....1688
Control Circut/Steering Motor....1689
HYDRAULIC SCHEMATIC....1690
Diagram....1692
MS-RT3020....1695
RT3020....1695
TABLE OF CONTENT....1696
M-IDX-2900-001....1698
M-IDX-2900-002....1699
M-IDX-2900-003....1700
M-IDX-2900-004....1701
SAFETY....1702
Safety Symbols used in the Manual....1704
General Maintenance and Repair Safety Notes....1704
Maintenance and Repair....1704
Before Leaving the Truck....1705
Before Carrying out Work on the Truck....1705
Before Operating the Truck....1705
Warnings and Labels on the Truck....1705
INTRODUCTION....1706
General....1708
Operating Instructions....1708
Service Training....1708
Ordering Spare Parts....1708
Using the Manual....1708
Page Numbering in the Manual....1709
Model-Number....1710
LUBRICATION AND ADJUSTMENT....1712
Jacking up the Truck....1714
Pictures....1714
Raising the Truck with a Crane....1715
Lifting the Truck with a second Truck....1715
Towing the Truck....1715
Component Access....1716
Picture....1716
Component Access, Picture....1717
Removing the Floorboard....1718
Removing the Side Panel....1718
Access to Drive Unit, Hydraulic System and Electrical Components....1718
Maintenance....1719
Driver Participation....1719
Daily Maintenance Log....1719
Recommended Lubricants and Oils....1719
Lubricants....1719
Cold Store Trucks....1719
Type Lubricant....1720
Grease Points, Overview....1721
Grease Points / Intervals....1722
Inspection and Maintenance Schedule....1722
Battery Maintenance....1722
Daily or every 8 service hours....1723
Picture....1724
Monthly or every 100 service hours....1725
Picture....1726
Every three months or 250 service hours....1727
Picture....1728
Every six months or 500 service hours....1729
Picture....1730
Annually or every 1000 service hours....1731
Every 2 years or 2000 service hours....1731
Picture....1732
Caster....1733
Torques....1734
HYDRAULICS....1736
Hydraulic System....1738
Operation....1738
Diagram....1738
Removing the Hydraulic Unit....1739
Picture....1739
Replacing the Hydraulic Pump....1740
Disassembly....1740
Assembly....1740
Start-up....1740
Pump Motor....1740
Replacing the Hydraulic Filter....1740
Replacing the Suction Filter....1740
Oil Change....1741
Diagram....1742
Valve Setting Control....1743
Non-return valve control....1743
Safety Valve Control....1743
Safety Valve Setting....1743
Picture....1744
DRIVE UNIT....1746
Drive Unit....1748
Preparation....1748
Removal....1748
Maintenance....1749
General....1749
Drive Unit Disassembly....1750
Assembly....1750
Adjusting the Bevel Wheel Set....1751
Basic Rules....1751
Checking the Flank Bearing....1751
Final Assembly....1751
Drive Unit Re-Installation....1752
Live Ring Bearing Replacement....1752
Forcing out the Live Ring Bearing....1752
Pressing in the Live Ring Bearing....1753
Installation of the Live Ring Bearing in the Drive Unit....1753
ELECTRICS....1754
Electrical Components....1756
Transmitter (MC,MN,PT)....1756
Fast / Slow Switch (HES)....1756
Seat Switch (MPD)....1756
Safety Pedal (PCT)....1756
Lift / Lower Switch (PCS, PCD)....1756
Lift Limit Switch (MFF)....1756
Pressure Switch (PS)....1756
Horn Switch (PCX)....1756
Horn (CX)....1756
Key Switch (QC)....1756
Emergency Disconnect Switch (PE)....1756
Steering Angle-Dependent Speed Reduction Microswitch....1756
Brake (FE)....1757
Fuses (F1, F2, FA)....1757
Traction Motor (M1)....1757
Pump Motor (M2)....1757
Pump Contactor (K3)....1757
Main Contactor (K4)....1757
Raise Contactor (RLS) and Lower Contactor (RLD)....1757
Steering Motor (M3), Option....1757
Encoder (MS), Option....1757
Steering Limit Switch (MF), Option....1757
Steering-Contactor (K6), Option....1757
Fuses (F3, FA3), Option....1757
Travel Direction Display (STD)....1757
Picture....1758
Picture....1759
ES1 Traction Controller....1760
General....1760
Precautionary Measures....1760
Operational Features....1760
Speed Control....1760
Reduced Speed Range....1760
Downhill Speed Control....1760
Regenerative Braking....1760
Anti - Roll Down Function....1760
Hourmeter....1761
Self Test....1761
Monitored Circuits....1761
Diagram....1761
Protective Devices....1762
Polarity Protection....1762
Wiring Errors....1762
Temperature....1762
Start Sequence....1762
Safety Class....1762
Maintenance....1762
ES1 Traction Controller Connections....1763
Programmer....1764
General....1764
Diagram....1764
Description of keys....1765
Operating Menu ZAPI ES1 Controller....1765
General....1765
Menu Functions....1765
Operating Menu - Overview....1766
PARAMETER CHANGE Menu....1767
Max. Speed Setting....1768
Speed Measurement....1769
TESTER Menu....1770
ALARMS Menu....1771
Error Code Display in SAM Hourmeter....1771
ALARMS Menu, diagram....1772
PROGRAM VACC Menu....1774
CONFIG Menu....1775
SAM Hourmeter....1776
Traction Controller Safety Test....1777
Battery....1778
General....1778
Operation....1778
Battery Replacement....1778
Battery Removal....1778
Replacing the Battery with a Crane....1779
Replacing the Battery with a Battery Trolley....1780
Charging the Battery....1781
Electric Motors....1782
General Maintenance Instructions....1782
Preparation....1782
Important Maintenance Instructions....1782
Traction Motor Maintenance....1783
Access to the brushes....1783
Maintenance....1783
Armature....1783
Bearings....1783
Pump Motor Maintenance....1784
Access to the Brushes....1784
Maintenance....1784
Steering Motor Maintenance....1785
Access to the Brushes....1785
Maintenance....1785
BRAKE....1786
Brake....1788
General Functional Description....1788
Removal....1788
Assembly....1789
Air Gap Setting....1789
Brake Moment Setting....1789
Brake Test....1790
RT3010 Nominal Braking Distances and Screw Depth....1790
STEERING....1792
Steering....1794
Operation....1794
Option....1794
Diagram....1794
Lower Steering Chain Adjustment....1795
Adjusting the Drive Unit Steering Chain....1795
Checking the Sliding Clutch....1796
Replacing the Sliding Clutch....1796
Steering Sensor Removal / Installation....1797
Steering Motor Removal / Installation....1797
Limit Switch Removal / Installation....1797
Diagram....1798
LIFTING MECHANISM....1800
Lifting Mechanism....1802
Test....1802
Adjusting the Stop....1802
Diagram....1803
CYLINDERS....1804
Cylinders....1806
General....1806
Plunger Cylinders (single-acting)....1806
Piston Cylinder (Double-Acting Cylinder)....1807
Single-Acting Cylinder, Picture....1808
Double-Acting Cylinder, Picture....1808
Maintenance....1809
Inspection....1809
Seal Installation....1810
General....1810
Lift Cylinder....1810
Removal Preparation....1810
Removal....1810
Repairing the Lift Cylinder....1811
Disassembly....1811
Inspection....1811
Assembly....1811
Assembly....1811
Gas Pressure Spring Removal and Assembly....1812
Removal Preparation....1812
Removal....1812
Assembly....1812
ELECTRICAL DIAGRAMS....1814
Control Circut....1816
Control Circut/Steering Motor....1817
HYDRAULIC SCHEMATIC....1818
Diagram....1820
SC....1823
9A133624 DIA-1140-001....1824
DIA-1140-001....1824
DIA-1140-002....1825
DIA-1140-003....1826
DIA-1140-004....1827
DIA-1140-005....1828
DIA-1140-006....1829
DIA-1140-007....1830
DIA-1140-008....1831
DIA-1140-009....1832
DIA-1140-010....1833
DIA-1140-011....1834
DIA-1140-012....1835
DIA-1140-013....1836
DIA-1140-013-SUP-1....1837
DIA-1140-013-SUP-2....1838
DIA-1140-013-SUP-3....1839
9A999999 DIA-1140-014....1840
DIA-1140-014....1840
DIA-1140-015....1841
DIA-1140-016....1842
DIA-1140-017....1843
DIA-1140-018....1844
DIA-1140-019....1845
DIA-1140-020....1846
DIA-1140-021....1847
DIA-1140-022....1848
DIA-1140-023....1849
DIA-1140-024....1850
DIA-1140-025....1851
DIA-1140-026....1852
DIA-1140-027....1853
DIA-1140-027-SUP-1....1854
DIA-1140-027-SUP-2....1855
DIA-1140-027-SUP-3....1856
Lube and adj M1.0-1140-011....1857
M1.0-1140-011....1857
M1.0-1140-012....1858
M1.0-1140-013....1859
M1.0-1140-014....1860
M1.0-1140-015....1861
M1.0-1140-016....1862
M1.0-1140-017....1863
M1.0-1140-018....1864
M1.0-1140-019....1865
M1.0-1140-020....1866
Lube and adj M1.0-1145-025....1867
M4.2-1140-001....1887
M4.2-1140-200....1891
Handset Operation....1891
Controller Settings....1893
M4.2-1140-400....1895
GEN II SX Troubleshooting....1895
Handset Operation....1895
Event Code Access....1896
Battery State of Charge....1896
Hour Meter....1897
Welding....1897
Recommended Lubrication of Pins and Sockets....1897
Initial Troublehsooting Instructions....1898
Controller Replacement Information....1898
Disabling RS232 Communications....1898
Setting Function Code 25....1898
Moving Handset From Controller To Controller....1899
Returing Truck To Service....1899
Event Code Display Description....1899
Slave Controller (MRC2) Event....1899
Master Controller (MRC1) Event....1899
No Code Displayed....1900
-01....1902
-02....1904
-03....1906
-04....1908
-05....1911
-06....1915
-08....1918
-09....1920
-10....1922
-11....1924
-12....1926
-14....1928
-15....1931
-16....1933
-17....1934
-18....1936
-21....1938
-23....1940
-24....1942
-25....1944
-27....1945
-28....1946
-30....1947
-31....1948
-32....1950
-33....1952
-34....1954
-35....1956
-36....1958
-37....1960
-40....1961
-41....1962
-42....1963
-43....1964
-44....1965
-45....1966
-46....1967
-49....1969
-51....1970
-57....1972
-63....1973
-64....1974
-65....1975
-66....1977
-68....1979
-76....1981
-77....1983
-82....1984
-83....1985
-84....1987
-85....1989
-86....1992
-99....1995
-201 thru -299....1995
-301 thru - 399....1995
M4.3-1140-006....1996
MS-SC3000....2001
SC3000....2001
TABLE OF CONTENT....2002
IDX-2230-001....2004
IDX-2230-002....2005
IDX-2230-003....2006
IDX-2230-004....2007
IDX-2230-005....2008
IDX-2230-006....2009
SAFETY....2010
Safety Symbols used in the Manual....2012
General Maintenance and Repair Safety Notes....2012
Maintenance and Repair....2012
Before Leaving the Truck....2013
Before Carrying out Work on the Truck....2013
Before Operating the Truck....2013
Warnings and Labels on the Truck....2013
INTRODUCTION....2014
Introduction....2016
General....2016
Using the Manual....2016
Sections Maintenance....2017
Page Numbers....2018
Operating instruction....2018
Service training....2018
Replacement parts orders....2018
Truck Data Numbering Sheet....2019
NOTE....2019
Battery Options....2020
NOTE....2020
LUBRICATION AND ADJUSTMENT....2022
Lubrication and Adjustment....2024
Access to Components....2024
Fig. B....2024
Figs. B1 and B2....2024
Fig. C....2024
Fig. D....2024
Fig. E....2024
Fig. F....2025
Fig. G....2025
Pictures (all)....2026
Jacking up the Truck....2027
Recommended Lubricants and Oils....2028
Lubricants....2028
Cold Store Trucks....2028
Driver Participation....2028
Daily Maintenance Log....2028
Lubricants and Oil Recommendations....2029
Inspection and Maintenance Schedule....2030
Daily or every 8 service hours....2031
Picture....2032
Monthly or ever 100 service hours....2033
Picture....2034
Every three months or 250 service hours....2035
Picture....2036
Annually or every 1000 service hours....2037
Picture....2038
Lubrication Points / Intervals....2039
Picture....2040
Torques....2041
Standard Screws and Nuts....2042
Umbrako Screws and Nuts....2042
Torques....2043
Torques (contd.)....2044
HYDRAULICS....2046
Hydraulic Symbols....2048
Hydraulic System....2052
General....2052
Hydraulic system diagram....2053
Operational Description....2054
Idle Mode....2054
Priority Valve....2054
Steering....2054
Lifting....2054
Tilting....2054
Control Valve....2055
Main Relief Valve Setting....2055
Maintenance and Repairs....2055
Pilot Valve Troubleshooting....2055
Unscrew valve cartridges....2056
Pump Motor....2057
Hydraulic Pump....2057
Commissioning....2057
Bleeding....2057
Oil Change....2057
DRIVE UNIT....2058
Truck Drive System....2060
Gear Unit....2060
Removal....2060
Drive Motor....2060
Removal....2060
Design....2061
Spur wheel bevel gear assembly....2061
Pre-assembly of the housing with flange shaft....2061
Bevel gear spur wheel pinion shaft pre-assembly....2061
Spur wheel flange shaft assembly....2061
Bevel gear assembly....2062
Bevel pinion assembly....2062
Flank tooth bearing....2063
Correcting the flank tooth bearing....2063
Reducing the installation path of the conical pinion....2063
Increasing the installation path of the conical pinion....2063
Maintenance....2064
Adding oil....2064
Types of oil....2064
Oil level....2064
Oil change....2064
ELECTRICS....2066
Electrical System....2068
Wire Colour Codes....2068
Tabel....2068
Switch Symbol Abbreviation List....2069
Sundry Abbreviations....2070
Electrical Symbols....2071
Electrical Components....2072
Switch Functions....2072
Brake Switch (BRS)....2072
Encoder (ENC), Encoder Module (EM)....2072
Accelerator Pedal Switch (ACS, POT1)....2072
Direction Indicator Switch (DIS)....2072
Handbrake Switch (HBS)....2072
Raise Potentiometer (POT2)....2072
Steering Axle Potentiometer (POT3)....2072
Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS)....2072
Emergency Disconnect....2072
Key Switch (KYS)....2072
Fuses (FU)....2072
Seat Switch (SES)....2073
Horn Switch (HNS)....2073
Electrical Components - Overview....2073
Zapimos B1S 48/700 Controller....2074
General....2074
Main Features....2074
Protective Devices....2074
Polarity Protection....2074
Wiring Errors....2074
Overheating....2074
Protection....2074
Key Terms....2074
Shunt or Shunt Resistor (+SH/-SH)....2074
Volt Motor Negative (VMN)....2074
Functional Description....2075
Acceleration / Delay Rate....2075
Travel Switch....2075
Travel Switch Signal Response ....2075
Fault Log....2075
Fault Identification....2075
Sparkless Contactors....2075
Inversion Braking....2075
Creep Mode....2075
Slow Travel....2075
Steering Controller....2075
45° Steering Angle....2076
MOSFET....2076
Pedal Braking (Inversion Braking with Battery Supply Regeneration)....2076
Pulse Width Modulation (PWM)....2076
Ramp Start....2076
Key Switch....2076
Self Test....2076
Reverse Travel Alarm....2076
Seat Switch....2076
Current Limit....2076
Overvoltage....2076
Overheating....2076
Low Voltage Reduction....2076
Connections ZAPIMOS B1S 48/700 Traction Controller....2077
Programmer Connection "B"....2078
Status LED "A"....2078
Status LED Diagnosis....2078
LED Code....2078
Control Line Connections....2079
ZAPIMOS B1S 48/700 Pin Layout....2080
Maintenance....2081
Cleaning the Traction Controller....2081
Removing / Installing the Traction Controller....2081
Installing the Traction Controller....2082
Zapimos HP 350A Pump Controller....2083
General....2083
Protective Devices....2083
Polarity Protection....2083
Wiring Errors....2083
Overheating....2083
Protection....2083
Key Terms....2083
Shunt or Shunt Resistor (+SH/-SH)....2083
Volt Motor Negative (VMN)....2083
Functional Description....2084
Acceleration / Delay Rate....2084
Current Limit....2084
Fault Identification....2084
Fault Log....2084
Hydraulic Function Switch....2084
Key Switch....2084
Lift Cut-Out....2084
Lift Potentiometer....2084
Lift Potentiometer Response....2084
Low Voltage Reduction....2084
MOSFET....2084
Overheating....2084
Overvoltage....2084
Pulse Width Modulation (PWM)....2084
Seat Switch....2085
Self Test....2085
Steer Support....2085
Connections ZAPIMOS HP 350A Pump Controller ....2085
Programmer Connection "B"....2086
Status LED "A"....2086
Status LED Diagnosis....2086
LED Code....2086
ZAPIMOS HP 350 A Pin Layout....2087
Maintenance....2087
Cleaning the Pump Controller....2087
Removing / Installing the Pump Controller....2088
Programmer....2090
General....2090
Description of keys....2091
Connecting the Programmer....2092
Operating Menu....2092
Traction Controller Operating Menu....2093
Programmer Start Routine....2094
Traction Controller Menu Functions....2095
PROGRAM....2095
TESTER....2095
ALARMS....2095
PROGRAM PEDAL....2095
CONFIG....2095
PROGRAM Menu....2096
TESTER Menu....2097
ALARMS Menu....2098
ALARMS Menu (continued)....2099
PROGRAM PEDAL Menu....2099
CONFIG Menu....2100
Pump Controller Operating Menu....2101
Menu Functions Pump Controller....2102
PROGRAM....2102
TESTER....2102
ALARMS....2102
PROGRAM VACC....2102
CONFIG....2102
PROGRAM Menu....2103
TESTER Menu....2104
ALARMS Menu....2105
ALARMS Menu (continued)....2106
CONFIG Menu....2107
Traction Controller Safety Test....2108
Pulse Monitor Trip Test (PMT)....2108
PMT Safety Test Wiring....2109
Battery....2110
General....2110
Operation....2110
Reading the Electrolyte Level....2110
Replacing the Battery....2110
Removing the Battery....2110
Charging the Battery....2110
Battery Discharge Indicator (BDI)....2112
General....2112
Adjusting the Battery Discharge Indicator....2112
Traction / Pump Motor Maintenance....2113
Access....2113
BRAKE....2114
Brake System....2116
General....2116
Operation....2116
Picture....2116
Replacing the Brake Disks and Linings....2117
Preparation....2117
Fig. M0253b....2117
Fig. M0254b....2117
Brake Disk and Lining Dimensions....2118
Removing the Brake Disks and the Friction Plates....2119
M0362....2120
Removing the Handbrake Cable....2121
Installation....2121
Adjusting the Operating Brake and Handbrake....2121
Preparation....2121
Adjusting the Operating Brake Air Gap....2121
Operating Brake Test....2122
Handbrake Adjustment....2122
STEERING....2124
Steering....2126
Hydraulic System....2126
Components....2126
Removing the Steering Motor....2127
Steering System Hydraulic Diagram....2127
Steering Axle....2128
Design....2128
Steering Drive Assembly....2128
Wheel hub pre-assembly....2128
Steering knuckle pre-assembly....2128
Steering knuckle and wheel hub assembly....2128
Spur pinion wheel shaft pre-assembly....2129
Housing Pre-Assembly....2129
Setting the Bearing Play....2130
Cylinder Pre-Assembly....2133
Fitting the Cylinders....2133
Assembling the Axle Bracket to the Steering Drive....2133
Operational and Leak Test....2133
Maintenance....2134
General....2134
Gear Lubricant....2134
Seals....2134
MAST....2136
Mast....2138
Disassembly....2138
Mast Roller Adjustment....2138
Fork Carriage Roller Adjustment....2140
Mast Roller Adjustment....2141
Checking the Mast Play....2141
Lift Chain Test....2142
General....2142
Maintenance....2142
Detailed Chain Testing....2143
Worn or Missing Plates....2143
Pitting and Corrosion....2143
Protruding or Turned Chain Pins....2143
Freedom of Movement and Worn Edges....2143
Measuring the Chain Elongation....2144
Chain Tension....2144
Chain Anchor and Pulleys....2144
Fork Tine Test....2145
General....2145
Fork Identification....2145
Repairs....2145
Crack Inspection....2145
VerticalityTest....2146
Fork Blade Warping....2146
Measuring the Fork Tip Width....2147
Fork Tine Height Difference....2147
Fork Stop....2147
Wear....2148
CYLINDERS....2150
Cylinders....2152
General....2152
Plunger Cylinders (single-acting cylinders)....2152
Piston Cylinder (Double-Acting Cylinder)....2153
Maintenance....2155
Inspection....2155
Installing the Piston Seal....2156
General....2156
Rod Seal Disassembly Tool....2156
Assembly of Small Rod Seals....2156
Assembly of Large Rod Seals....2156
ELECTRICAL DIAGRAMS....2158
Key....2160
Connectors....2160
Contactors....2160
Abbreviations....2160
Control Circuit....2161
Power Circuit....2162
Traction Controller....2163
Pump Controller....2164
Seat Switch and Steer Pot....2165
Control Levers....2166
B.D.I., Horn and Brake Switches....2167
Steer Column....2168
Star Points....2169
Panel Wiring....2170
Power Cables....2171
Part Numbers for Connectors and Looms....2172
HYDRAULIC SCHEMATIC....2174
Diagram....2176
Pot Calibration M4.3-1140-200....2179
Handset....2179
ACC POT....2180
STR POT....2181
Brake Resistor Module....2183
Auto Calibration of Potentiometers....2184
SC 4000 Trouble codes M4.2-1140-400....2186
GEN II SX Troubleshooting....2186
Handset Operation....2186
Event Code Access....2187
Battery State of Charge....2187
Hour Meter....2188
Welding....2188
Recommended Lubrication of Pins and Sockets....2188
Initial Troublehsooting Instructions....2189
Controller Replacement Information....2189
Disabling RS232 Communications....2189
Setting Function Code 25....2189
Moving Handset From Controller To Controller....2190
Returing Truck To Service....2190
Event Code Display Description....2190
Slave Controller (MRC2) Event....2190
Master Controller (MRC1) Event....2190
No Code Displayed....2191
-01....2193
-02....2195
-03....2197
-04....2199
-05....2202
-06....2206
-08....2209
-09....2211
-10....2213
-11....2215
-12....2217
-14....2219
-15....2222
-16....2224
-17....2225
-18....2227
-21....2229
-23....2231
-24....2233
-25....2235
-27....2236
-28....2237
-30....2238
-31....2239
-32....2241
-33....2243
-34....2245
-35....2247
-36....2249
-37....2251
-40....2252
-41....2253
-42....2254
-43....2255
-44....2256
-45....2257
-46....2258
-49....2260
-51....2261
-57....2263
-63....2264
-64....2265
-65....2266
-66....2268
-68....2270
-76....2272
-77....2274
-82....2275
-83....2276
-84....2278
-85....2280
-86....2283
-99....2286
-201 thru -299....2286
-301 thru - 399....2286
SC3200....2287
SC3200....2287
REVISION....2289
TABLE OF CONTENT....2293
Table of Content 1....2293
Table of Content 2....2294
Table of Content 3....2295
Table of Content 4....2296
Table of Content 5....2297
Table of Content 6....2298
Table of Content 7....2299
Table of Content 8....2300
SAFETY....2303
Safety Symbols used in the Manual Safety Notes....2303
General Maintenance and Repair Safety Notes....2303
Maintenance and Repair....2303
Before Leaving the Truck....2304
Before Carrying out Work on the Truck....2304
Before Operating the Truck....2304
Warnings and Labels on the Truck....2304
INTRODUCTION....2307
General....2307
Operating Instructions....2307
Service Training....2307
Ordering Spare Parts....2307
Using the Manual....2307
A01M-gb....2307
Model-Number....2308
LUBRICATION AND ADJUSTMENT....2311
Lifting the Truck....2311
Lifting by Crane....2311
G_SC32-Heben-Kran....2311
Lifting by another truck....2311
G_SC32-Heben-seitl....2311
Towing the Truck....2312
Jacking up the Truck....2312
MO-2232-035....2312
Counterweight....2313
Disassembly....2313
Tools required:....2313
Assembly....2314
Lubrication and Adjustment....2315
Component Access....2315
MO-2232-037....2315
MO-2232-038....2315
MS-2232-040....2316
MS-2232-043....2316
MS-2232-039....2316
MS-2232-038....2316
MS-2232-042....2316
MS-2232-041....2316
Fig. A: Battery compartment lid....2317
Provides access to:....2317
Access:....2317
Fig. B: Steering column front panel....2317
Provides access to:....2317
To remove:....2317
Fig. E: Inner dashboard....2317
Provides access to:....2317
To remove:....2317
Fig. C: Valve and Control Handle Panel....2317
Provides access to:....2317
To remove:....2317
When you have lifted out the floor boards you will have access to:....2317
To remove the floor boards:....2317
Recommended Lubricants and Oils....2318
Lubricants....2318
Cold Store Truck Lubricants....2318
Taking the truck out of service....2318
Bringing the truck back into service....2318
L62-GB....2319
L63-GB....2320
Inspection and Maintenance Schedule....2321
Daily Maintenance (or every 8 service hours) L70-GB ....2322
MS-2232-045....2323
MS-2232-044....2323
MS-2232-038....2323
M0324....2323
Monthly Maintenance or every 100 service hours L71-GB....2324
MS-2232-046....2324
MS-2232-044....2325
M0324....2325
3-Monthly Maintenance (or every 250 service hours) L72-GB....2326
6-Monthly Maintenance (or every 500 service hours) L73-GB....2328
Annual Maintenance (or every 1000 service hours) L74-GB....2328
2-Yearly Maintenance (or every 2000 service hours) L75-GB....2328
MS-2232-047....2329
MS-2232-039....2329
MS-2232-038....2329
Torque Requirements....2330
WARTUNG 07....2330
Standard Torque Tables T58-GB....2330
Hex. countersunk screws T59-GB....2331
Hex. head screws T60-GB....2332
Umbrako screws and nuts T61-GB....2333
Special Torque Tables....2334
Torque Settings MECHANICAL T56_1-GB....2334
Torque Settings HYDRAULIC T56_2-GB....2335
Torque Settings ELECTRICAL T56_3-GB....2335
Specific Fastener Torque Requirements T57_1-GB....2336
Specific Fastener Torque Requirements T57_2-GB....2337
HYDRAULICS....2341
Hydraulic Symbols 1....2341
Hydraulic Symbols 2....2342
Hydraulic Symbols 3....2343
Hydraulic Symbols 4....2344
Valve Block....2345
Pump motor....2345
Hydraulic pump....2345
Commissioning....2345
Bleeding....2345
Oil Change....2345
Bleeding the hydraulic system....2346
Bleeding the tilt cylinders....2346
Bleeding the free lift cylinder....2346
Bleeding the lift cylinders....2346
Flushing the cylinders....2347
Drift Tests....2347
Lift cylinder drift test....2347
Tilt cylinder drift test....2347
Steer unit drift test....2347
Overload Valves (RV)....2348
Drive Unit....2351
Gear Unit....2351
Disassembly....2351
MS-2232-100....2351
Disassembly....2351
Assembly....2351
MP-2232-016....2352
General....2353
Dismantling the Gear Unit....2353
Gear Unit Assembly....2353
Pre-assembly of the housing with flange shaft MS-2232-101....2353
Bevel gear spur wheel pinion shaft pre-assembly....2353
Spur wheel flange shaft assembly MS-2232-102....2353
Bevel gear assembly....2354
Bevel pinion assembly MS-2232-103....2354
MS-2232-104....2354
Flank tooth bearing....2355
Correcting the flank tooth bearing....2355
M1565-1....2355
Maintenance....2355
Adding oil....2355
Types of oil....2355
Oil level....2355
Oil change....2355
ELECTRICS....2359
Electrics - General....2359
Wire Colour Codes E01-gb....2359
Abbreviations E02-gb....2360
Electrical Symbols M0056-gb....2361
Electrical Components....2363
Switch Functions....2363
Brake Switch (BRS)....2363
Encoder (ENC), Encoder Module (EM)....2363
Accelerator Pedal Switch (ACS, POT1)....2363
Direction Indicator Switch (DIS)....2363
Handbrake Switch (HBS)....2363
Raise Potentiometer (POT2)....2363
Steering Axle Potentiometer (POT3)....2363
Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS)....2363
Emergency Disconnect....2363
Key Switch (KYS)....2363
Fuses (FU)....2363
Seat Switch (SES)....2364
Electrical Components - Overview....2364
Horn Switch (HNS)....2364
Electrical Components - Overview....2364
M0369....2364
M0367....2364
M0368....2364
Electrical Board....2365
Zapimos B1S 48/700 Controller....2367
General....2367
M0201....2367
Protective Devices....2367
Polarity Protection....2367
Wiring Errors....2367
Overheating....2367
Protection....2367
Key Terms....2367
Shunt or Shunt Resistor (+SH/-SH)....2367
Volt Motor Negative (VMN)....2367
Functional Description....2367
Acceleration / Delay Rate....2367
Travel Switch....2367
Travel Switch Signal Response....2367
Fault Log....2367
Fault Identification....2367
Sparkless Contactors....2368
Inversion Braking....2368
Creep Mode....2368
Slow Travel....2368
Steering Controller....2368
45° Steering Angle....2368
Pedal Braking (Inversion Braking with Battery Supply Regeneration)....2368
Ramp Start....2368
Key Switch....2368
Self Test....2368
Reverse Travel Alarm....2368
Seat Switch....2369
Current Limit....2369
Overvoltage....2369
Overheating....2369
Low Voltage Reduction....2369
ZAPIMOS B1S 48/700 Traction Controller Connections....2370
ZAPIMOS B1S 48/700 Pin Layout....2371
Programmer Connection "B"....2373
Status LED "A"....2373
Status LED Diagnosis....2373
E55-GB....2373
ZAPIMOS HP 350A Pump Controller....2374
General....2374
Protective Devices....2374
Polarity Protection....2374
Wiring Errors....2374
Overheating....2374
Protection....2374
Key Terms....2374
Shunt or Shunt Resistor (+SH/-SH)....2374
Volt Motor Negative (VMN)....2374
Functional Description....2375
Acceleration / Delay Rate....2375
Hydraulic Switches....2375
Lift Cutout....2375
Lift potentiometer....2375
Lift Potentiometer Response....2375
Fault Log....2375
Fault Identification....2375
Steering Support....2375
Key Switch....2375
Self Test....2375
Current Limit....2375
Overvoltage....2375
Overtemperature....2375
Low Voltage Reduction....2375
ZAPIMOS HP 350A Pump Controller Connections MS-2232-051....2376
ZAPIMOS HP 350 A Pin Layout....2377
Pump Controller, LED error code....2378
Programmer Connection "B"....2378
Status LED "A"....2378
Status LED Diagnosis....2378
E67-GB....2378
Pump Controller Removal....2379
Pump Controller Assembly....2379
M0189....2379
Traction Controller Removal....2379
Traction Controller Assembly....2380
Programmer....2381
General....2381
MS-2232-034....2381
E54-GB....2382
MS-2232-023....2382
Connecting the Programmer....2383
M0272....2383
Operating Menu....2383
General....2383
Traction Controller Operating Menu....2384
Programmer Start Routine M0288d....2385
Traction Controller Menu Functions....2386
PROGRAM....2386
TESTER....2386
ALARMS....2386
PROGRAM PEDAL....2386
CONFIG....2386
PROGRAM Menu E53-GB....2387
TESTER Menu E52-GB....2388
ALARMS Menu....2389
ALARMS Menu (traction controller) E50_1-GB....2389
ALARMS Menu (traction controller) E50_2-GB....2390
ALARMS Menu (traction controller) E50_3-GB....2391
PROGRAM PEDAL Menu....2391
CONFIG Menu E69-GB....2392
Pump Controller Operating Menu....2393
Menu Functions Pump Controller....2394
PROGRAM....2394
TESTER....2394
ALARMS....2394
PROGRAM VACC....2394
CONFIG....2394
PROGRAM Menu....2395
Traction Controller Settings E68_1-GB....2395
Traction Controller Settings E68_2-GB....2396
Traction Controller Settings E68_3-GB....2397
Traction Controller Settings E68_4-GB....2398
TESTER Menu....2399
TESTER Menu (pump controller) E51-GB....2399
ALARMS Menu....2400
ALARMS Menu (Pump controller) E64-GB....2400
ALARMS Menu (Pump controller) E65-GB....2401
ALARMS Menu (Pump controller) E66-GB....2402
PROGRAM VACC Menu....2402
CONFIG Menu E76-GB....2403
Calibrating the Steering Potentiometer....2404
Preparation....2404
Calibration....2404
MS-2232-035....2404
Calibrating the Lift Potentiometer....2405
Preparation....2405
Calibration....2405
MS-2232-056....2405
Calibrating the Accelerator Potentiometer....2406
Preparation....2406
Calibration....2406
MS-2232-055....2406
Traction Controller Safety Test....2408
Pulse Monitor Trip Test (PMT)....2408
Equipment....2408
Test....2408
PMT Safety Test Wiring....2409
M0341....2409
Battery....2410
General....2410
Replacing the battery....2410
Battery Discharge Indicator (BDI)....2410
General....2410
Battery Discharge Indicator Setting (BDI)....2411
Calibration....2411
E77-GB....2411
Electric Motors....2412
General Maintenance Instructions....2412
Preparation....2412
Important Maintenance Instructions....2412
Traction Motor Maintenance....2413
MS-2232-039....2413
Access to Brushes....2413
MS-2232-053....2413
Maintenance....2413
Armature....2413
Bearings....2413
Pump Motor Maintenance....2414
MS-2232-052....2414
Access to brushes....2414
M0076....2414
Maintenance....2414
Armature....2414
BRAKE....2417
Brakes....2417
General....2417
MS-2232-002....2417
Brake Lining Wear Limits....2417
MS-2232-010....2417
Brake Removal....2417
MS-2232-004....2417
Right brake....2418
Left brake....2418
MS-2232-007....2418
MS-2232-006....2419
Brake Assembly....2419
Before Assembling....2419
Assembly....2419
Foot Brake....2420
Foot Brake Adjustment....2420
MS-2232-008....2420
MS-2232-009....2420
Checking the braking distance....2420
Handbrake Adjustment....2421
MS-2232-003....2421
STEERING....2425
Steering....2425
Hydraulics....2425
Function....2425
MS-2232-058....2425
Steering Components....2426
MS-2232-059....2426
Steering wheel....2427
Disassembly....2427
MS-2232-060....2427
Assembly....2427
Direction Control Switches....2428
MS-2232-061....2428
Switch Removal....2428
Switch Assembly....2428
Steer Sensor Module....2430
Disassembly....2430
Assembly....2430
Steering Sensor....2430
Disassembly....2430
Assembly....2430
MP-2232-010....2430
Steering Column Adjustment....2431
Gas Pressure Cylinder Removal....2431
MS-2232-063....2431
Gas Pressure Cylinder Assembly and Adjustment....2431
MS-2232-064....2431
Steering column....2432
Disassembly....2432
Steering Column Removal....2432
Removing the steering shaft from the steering column....2432
Replacing the slip rings....2432
MS-2232-062....2432
MP-2232-008....2433
Steering Gear Removal....2434
M0118....2434
Steering axle....2435
Design....2435
M1248....2435
Steering Gear Assembly....2435
Wheel hub pre-assembly....2435
Steering knuckle pre-assembly....2435
Steering Knuckle and Wheel Hub Assembly....2435
Spur pinion flange shaft pre-assembly....2436
M1249....2436
Housing pre-assembly....2436
M1250....2436
M1251....2436
M1252....2436
M1253....2437
M1254....2437
Adjusting the bearing clearance....2437
M1256....2437
M1255....2437
M1258....2438
M1257....2438
M1259....2438
M1260....2438
M1261....2439
M1262....2439
M1263....2439
M1264....2439
M1265....2440
Cylinder Pre-Assembly....2440
Inserting the cylinder....2440
M1266....2440
Assembling the Axle Bracket to the Steering Gear....2440
M1267....2440
Operational and Leakage Test....2441
After re-installing in the truck:....2441
Steering axle 2.12.01.1 MP-2232-006....2442
Steering axle 2.12.09.0 MS-2232-065....2443
MAST....2447
Mast (TT Series)....2447
General....2447
Torques....2447
Mast bearing mounting screws....2447
MS-2232-011....2447
Mast Stoppers....2447
Lifting Gear Minimum Capacity....2447
Mast Testing (Assembled)....2447
Flaking....2447
MP-2232-028....2448
Mast Disassembly....2449
Dismantling the Mast (Attached)....2449
General....2449
MP-2232-028....2450
Fork Carriage Removal....2451
MP-2232-027....2451
Free Lift Cylinder Removal....2451
MP-2232-028....2452
Removing the individual mast stages....2453
Replacing the Mast Rollers on the Mast Stages and the Fork Carriage....2453
Mast Stage Rollers....2453
MP-2232-028....2454
Fork Carriage Mast Rollers....2455
Lift Cylinder Removal....2455
Removing the Mast from the Truck....2456
MS-2232-011....2456
MS-2232-012....2456
Mast Assembly....2457
Lift Chains....2458
General....2458
Inspection....2458
Cleaning....2458
Wear....2458
Fig. 2271....2459
Freedom of Movement of Chain Links 2775si....2459
Chain Tension....2459
Chain Anchor and Pulleys 2774si....2460
Worn Connection Plates....2460
Protruding or Turned Chain Pins 2776si....2460
Corrosion 2773si....2460
Chain Lateral Wear....2461
Uneven Chain Tension....2461
Misalignment of Lift Components....2461
Lift Chain Lubrication....2462
277si....2462
Detaching Lift Chains....2463
Tools and Equipment Required....2463
Detachment....2463
Fork Tines....2464
General....2464
Terms....2464
M0344....2464
Fork Identification....2464
M0345....2464
Repairs....2464
Checking the Fork....2464
Crack Inspection....2464
M0346, M0347....2464
Verticality Test....2465
M0350....2465
Fork Blade Warping....2465
M0353....2465
Measuring the Fork Tip Width....2465
M0355....2465
Fork Tine Height Difference....2465
M0354....2465
Stop Mechanism....2466
M0356....2466
Fork Blade Wear....2466
M0357....2466
MS-2232-013....2466
Sideshifter....2467
General....2467
MS-2232-030....2468
Integrated Sideshifter....2469
Removal, Repair and Assembly....2469
MS-2232-031....2470
MS-2232-032....2470
Hook-on Sideshifter....2471
Removal, Repair and Assembly....2471
Before re-assembling the fork carriage in the reverse order....2471
After assembly:....2471
CYLINDERS....2475
Cylinders....2475
General....2475
Safety when working on hydraulic systems....2475
General Instructions for Repairing Hydraulic Components....2475
Rod Seal Assembly....2476
General....2476
MS-2232-013....2476
MS-2232-016....2476
Large Rod Seal Assembly....2476
Tools required:....2476
Assembly:....2476
MS-2232-019....2476
MS-2232-020....2476
MS-2232-022....2477
MS-2232-021....2477
Small Seal Rod Assembly....2477
Tools required:....2477
MS-2232-024....2477
Rod Seal Assembly, Sealing Lip First....2478
MS-2232-025....2478
Tilt Cylinders....2479
General....2479
Removal....2479
Tilt Cylinder Sectional Drawing....2480
MS-2232-014....2480
MP-2232-031....2481
Dismantling....2482
Component Inspection....2482
Assembly....2482
MP-2232-031....2483
Assembly....2484
MP-2232-024....2486
Lift Cylinders....2487
General....2487
Removal and Assembly....2487
Dismantling....2487
Rod Seal Removal....2487
MS-2232-015....2487
MS-2232-016....2487
MP-2232-024....2488
Piston Rod Removal....2489
Assembly....2489
Piston Rod Assembly....2489
Installing the Rod seal....2489
MS-2232-018....2489
MP-2232-025....2490
Free-Lift Cylinder....2491
General....2491
Removal and Assembly....2491
Dismantling....2491
Rod Seal Removal....2491
Piston Rod Removal....2491
Assembly....2491
Piston Rod Assembly....2491
Installing the Rod Seal....2491
MP-2232-025....2492
MP-2232-004....2494
MS-2232-028....2494
Hook-on Sideshifter, Cylinder....2495
MS-2232-026....2495
MS-2232-027....2495
MP-2232-030....2496
Integrated Sideshifter, Cylinder....2497
DIAGRAMS....2501
Key....2501
Connectors....2501
Contactors....2501
Abbreviations....2501
Control Circuit, 796324_2a_1_2....2503
Power Circuit, 796324_2a_2_2....2504
Option Brush Wear & Over Temperature Indicator Circuit Diagram....2505
Option Lighting Diagram, 813070_2e_1_1....2506
Cold Store Option, 810350_2b_1_1....2507
Seat Switch and Steer Pot, 814590_2a_1-8....2508
Steer Column, 814590_2a_2-8....2508
BDI, Horn and Brake Switches, 814590_2a_3-8....2509
Control Levers, 814590_2a_4-8....2509
Star Points, 814590_2a_5-8....2510
Panel Wiring, 814590_2a_6-8....2510
Traction Controller, 814590_2a_7-8....2511
Pump Controller, 814590_2a_8-8....2511
Power Cable Diagram, 813167_2b_1_1....2512
Main Loom, Part 1, doc-794929_f_2_3....2513
Main Loom, Part 2, 794929-1_T-GB, 794929-2_T-GB, doc-794929_f_3_3....2514
Steer Column Loom, 810209_T-GB, 810209_e....2515
Fan Standard, 794878_T-GB, doc-794878_b....2516
Option: Main Harness, Middle East Fan, 132427_T-GB, doc-132427_a....2517
Option Lights, Main Loom Lights, 813072-t-DE, doc-813072_a....2518
Option Lights, Panel to Switch, 813071-T-GB, doc-813071_a....2519
Option Lights, Module to Panel, 794314_T-GB, doc-794314_c....2520
Option Lights, Panel to Main Loom Lights, 793794_T-GB, doc-793794_b....2521
Option Lights, Reverse Alarm to Module, 793803_T-GB, doc-793803_b....2522
Option, Brush Wear and Overtemperature Display Loom, 793896_T -DE, doc-793896_c_2_2....2523
Option, 5th Hydraulic Function, 127511_T-GB, doc-127511_c....2524
Option, Cold Store Model Additional Loom, Part 1 of 2, 794588-T-GB, doc-794588_e_2_3....2525
Option, Cold Store Model Additional Loom, Part 2 of 2, 794588-T-GB, doc-794588_e_3_3 ....2526
Option, Cold Store Model Additional Loom, Heating Control Module, 810263_t-GB, doc-810263_b....2527
HYDRAULICS....2531
Based on: 808819_2d_1_1....2531
SC4000....2533
SC4500 Brake release F016819....2634
Tune up M4.2-1140-200....2635
Handset Operation....2635
Controller Settings....2637
Mode 2 is 90 mode 3 id 175....2637
SP....2639
SP 3000 series part 1.service.parts.uk....2640
SP 3000 series part 2.service.parts.uk....2892
SP 3500.operations.uk....3134
SP3400 Four-Point Service....3156
SP 3400 SERIES Four-Point....3156
Safety....3172
Symbols Used in the Manual....3174
Safety Symbols....3174
General Symbols....3174
Fork direction....3174
General Safety Instructions....3175
Maintenance and Repair Instructions....3175
Maintenance and Repair....3175
Before Parking the Truck....3175
Before Working on the Truck....3175
Before Starting the Truck....3175
Warning and Instruction Decals on the Truck....3176
Control of Hazardous Energy....3177
Battery....3177
Safety Rules....3177
Battery Removal....3178
Battery Installation....3178
Lockout - Tagout....3179
Brake....3179
Capacitance....3180
Hydraulic System....3181
Depressurising the hydraulic system....3181
Accumulator....3182
Lifting and Blocking....3183
Required tools....3183
Raising the Side....3183
Raising the Drive Wheel....3184
Blocking Mast Stages....3185
Cleaning Methods....3186
Introduction....3188
General....3190
Operating Instructions....3190
Service Training....3190
Ordering Spare Parts....3190
Using the Manual....3190
Data Plate....3191
Lubrication & Adjustment....3194
Lubricants....3196
Maintenance....3200
General....3200
Component Accessibility....3200
Componentry....3212
Accumulator....3213
ALM1....3213
BRES1, BRES2....3213
BRK1....3213
BRS1....3213
CHS1, CHS2....3215
CHS3, CHS4....3215
CV1....3215
CV2....3215
CV3....3215
Free Lift Cylinder....3215
Mast Cylinders....3215
DCM....3217
DPS....3217
DTS1....3217
ECR1....3217
ECR2....3217
ECR3....3217
ECR4....3217
ED1....3219
ED2....3219
EDS....3219
Fan....3219
Filter....3219
FNS....3219
FS....3219
FU1....3221
FU2....3221
FU3....3221
FU4....3221
FU5....3221
FU6....3221
FU8....3221
FU9....3221
FU10....3223
FU11....3223
FU12....3223
FU13....3223
GCM....3223
GTS1, GTS2....3223
GTS5, GTS6....3223
GUS....3223
HN1....3225
HN2....3225
HNS1....3225
HSLCS....3225
K1....3227
K2....3227
K5....3227
K11....3227
K12....3227
KYS....3229
LCS1....3229
LGS1....3229
LGS2....3229
LGS3....3229
LGT1....3229
LGT2, 5....3229
LGT3, 6....3231
LGT4, 7....3231
LOS1....3231
LOS2....3231
M1....3231
M2....3231
M3....3231
M4....3231
MRC1....3233
MVL....3233
ORS1....3233
P1....3233
P1 Pump....3233
P2....3233
P2 Pump....3233
POT1....3235
PS1....3235
PS2....3235
PVL....3235
RAS1....3235
RAS2....3235
RCS1, RCS2....3235
RES1....3237
RES2, RES3....3237
RES4, RES5....3237
RES6, RES7....3237
RES8, RES9....3237
RES10....3237
RES11....3237
RES12....3239
RES13....3239
RES14....3239
RES15, RES19....3239
RES16....3239
RES20, RES21....3241
RES23....3241
RESERVOIR....3241
RGS1, RGS2....3241
RS....3241
RV1....3241
SB10....3243
SB11....3243
SB21....3243
SB30....3243
SCM....3243
Sensor bar Loadwheel....3245
Sensor Bar Steered Wheel....3245
Strainer....3245
Test Port....3245
THS2....3245
THS3....3245
ZSS....3245
Truck Installation....3247
Caster Assembly....3249
Adjustment....3249
Torque Values....3250
Hydraulic System....3252
Hydraulic Symbols....3254
General....3258
Reservoir....3258
Hydraulic Lines and Fittings....3259
Filter....3259
Freezer Preparation....3260
Drift Test....3261
Lift Drift Test....3261
Circuit Descriptions....3262
Lift Circuit - Two Speed Lift....3262
Low Speed Lift....3262
High Speed Lift....3262
Relief Valve Operation....3262
Accumulator Operation....3262
Lower Circuit - One Speed/Two Speed Lower....3263
Lower....3263
Manual Lower -Two Speed Lift/Lower....3264
Pump Repair....3265
Pump - Gear....3265
Oil Seal Removal....3265
Oil Seal Replacement....3266
Pump Disassembly....3266
Parts Inspection....3266
Body....3266
Composite Bushings....3266
Gears....3267
End Cover....3267
Mounting Flange....3267
Pump Reassembly....3268
Start Up Procedure....3269
Accumulator....3270
Precharging....3270
Hydraulic Troubleshooting....3272
Drive Unit....3276
Drive Tire....3278
Replacement....3278
Lubrication....3279
Oil Pump....3280
Disassembly....3280
Assembly....3280
Removal & Installation....3281
Electrical System....3282
Relays....3284
K1....3284
Power Up Relay....3284
K2....3284
Module Power....3284
K5....3284
Steer Motor Relay....3284
K11 & K12....3285
Freezer/Condition Relays....3285
Encoders....3286
Electrical Wiring....3288
Wiring Color Codes....3288
Color....3288
Number....3288
Power Cables....3288
Basic Symbols....3290
Motor Monitoring System (MMS)....3292
Overtemperature Sensors....3292
Brushwear Sensors....3293
Tune Up....3296
Service Terminal....3296
Description....3296
Service Terminal Operation....3296
Keyboard Commands....3297
Main Menu....3298
Calibration - Truck Setup Menu....3300
Calibration - Lift Cutouts or Zone Menus....3301
Calibration - Truck Options Menu....3302
Calibration - P.M. Interval Setup Menu....3303
Calibration - Hourmeter Reset Menu....3304
Calibration - Wire Guidance Menu....3305
Calibration - Traction Setup Menu....3306
Calibration - Traction Setup/Features Menus....3307
Calibration - Traction Setups/Performance Menus....3309
Calibration - Traction Setups/Performance Menus (Cont’d)....3310
Display....3313
Erase....3314
Show....3315
Show - System Information Menus....3316
Show - View Enable Config Menus....3317
Show - Truck Monitors Menus/View Encoder Counts Menus....3318
Show - View Switch Status Menus/View System Constants Menus....3319
Show - View Hardware Outputs Menus....3321
Show - View Hourmeter Data Menus/View Wire Guide Sensors Menus....3322
Show - Traction Analyzer Menus....3323
Show - Status Analyzer Menus....3324
Show - Traction Inputs Menus....3325
Show - View Switches Menus....3326
Show - Traction Outputs Menus....3328
Traction Setup Performance Values....3329
Motors....3331
Display and Steering Modules....3334
Message Display....3334
Power "ON" LED's (green)....3335
Service LED's (amber)....3335
Torque Requirements for Steering Module Terminations....3336
Contactor....3338
Inspection....3338
Contacts....3338
Coil....3338
Component Replacement....3339
Contact Replacement....3339
Coil Replacement....3339
Steering Feedback....3340
Gear Assembly....3340
Battery....3342
Safety Rules....3342
Checking....3342
Battery Care....3343
Charging....3344
Battery Removal....3346
Battery Installation....3347
Battery Cleaning....3348
Troubleshooting....3348
Event Codes....3349
Some Troubleshooting Basics....3349
Check the Event Code Listing....3349
No Event Code?....3349
To Locate Malfunctioning Components....3349
Test Points....3349
Event Codes....3349
Event Code 201 - 202....3350
Event Code 201 - 202....3350
Event Code 202....3350
Event Code 204....3351
Event Code 208....3352
Event Code 209 - 210....3354
Event Code 209....3354
Event Code 210....3354
Event Code 211 - 212....3355
Event Code 211....3355
Event Code 212....3355
Event Code 213....3356
Event Code 215....3357
Event Code 216....3358
Event Code 217....3359
Event Code 218....3360
Event Code 219 & 221....3361
Event Code 219....3361
Event Code 221....3361
Event Code 222 - 223....3362
Event Code 222....3362
Event Code 223....3362
Event Code 224 & 227....3363
Event Code 224....3363
Event Code 227....3363
Event Code 228, 311 - 314....3364
Event Code 228....3364
Event Code 311....3364
Even Code 312....3364
Event Code 313....3364
Event Code 314....3364
Event Code 315....3365
Event Code 316 - 317....3366
Event Code 316....3366
Event Code 317....3366
Event Code 318....3367
Event Code 319 & 321....3368
Event Code 319....3368
Event Code 321....3368
Event Code 322 - 323....3369
Event Code 322....3369
Event Code 323....3369
Event Code 324 & 326....3370
Event Code 326....3370
Event Code 327....3371
Event Code 328....3372
Event Code 331....3373
Event Code 332....3374
Event Code 333....3375
Event Code 334 - 336....3376
Event Code 334....3376
Event Code 335....3376
Event Code 336....3376
Event Code 337 & 339....3377
Event Code 337....3377
Event Code 339....3377
Event Code 341 - 343....3378
Event Code 341....3378
Event Code 342....3378
Event Code 343....3378
Event Code 344....3379
Event Code 345....3380
Event Code 346....3381
Event Code 347 - 348....3382
Event Code 347....3382
Event Code 348....3382
Event Code 349 & 351....3383
Event Code 349....3383
Event Code 351....3383
Event Code 352....3384
Event Code 353 - 354....3385
Event Code 353....3385
Event Code 354....3385
Event Code 355 - 358 & 362....3386
Event Code 355....3386
Event Code 356....3386
Event Code 357....3386
Event Code 358....3386
Event Code 362....3386
Event Code 363 - 364....3387
Event Code 363....3387
Event Code 364....3387
Event Code 365 - 367....3388
Event Code 365....3388
Event Code 366....3388
Event Code 367....3388
Event Code 368 - 369, 371 - 373....3389
Event Code 368....3389
Event Code 369....3389
Event Code 371....3389
Event Code 372....3389
Event Code 373....3389
Event Code 374 - 377....3390
Event Code 374....3390
Event Code 375....3390
Event Code 376....3390
Event Code 377....3390
Event Code 378 - 379....3391
Event Code 378....3391
Event Code 379....3391
Event Code 381 - 383....3392
Event Code 382....3392
Event Code 383....3392
Event Code 384....3393
Event Code 385 - 388....3394
Event Code 385....3394
Event Code 386....3394
Event Code 387....3394
Event Code 388....3394
Event Code 391 - 394....3395
Event Code 391....3395
Event Code 392....3395
Event Code 393....3395
Event Code 394....3395
Event Code 396 - 399....3396
Event Code 396....3396
Event Code 397....3396
Event Code 398....3396
Event Code 399....3396
Event Code 411 - 416....3397
Event Code 411....3397
Event Code 412....3397
Event Code 413....3397
Event Code 414....3397
Event Code 415....3397
Event Code 416....3397
Event Code 417 - 418....3398
Event Code 417....3398
Event Code 418....3398
Event Code 419....3399
Event Code 421....3400
Event Code 422....3402
Event Code 423....3403
Event Code 424....3404
Event Code 425....3405
Event Code 426....3406
Event Code 427....3407
Event Code 428 - 429....3408
Event Code 428....3408
Event Code 429....3408
Event Code 431 - 435....3409
Event Code 431....3409
Event Code 432....3409
Event Code 433....3409
Event Code 434....3409
Event Code 435....3409
Event Code 436 - 438....3410
Event Code 436....3410
Event Code 437....3410
Event Code 438....3410
Event Code 439....3411
Event Code 441 - 442....3412
Event Code 441....3412
Event Code 442....3412
Event Code 800 - 802....3413
Event Code 800....3413
Event Code 801....3413
Event Code 802....3413
Event Code 803 - 804....3414
Event Code 803....3414
Event Code 804....3414
Event Code 805 - 806....3415
Event Code 805....3415
Event Code 806....3415
Event Code 807....3416
Event Code 808....3417
Event Code 809....3418
Event Code 810 - 814....3419
Event Code 810....3419
Event Code 811....3419
Event Code 812....3419
Event Code 813....3419
Event Code 814....3419
Event Code 827....3420
Event Code 828....3421
Event Code 829....3422
Event Code 831....3423
Event Code 832 - 834....3424
Event Code 83....3424
Event Code 833....3424
Event Code 834....3424
Event Code 835 - 838....3425
Event Code 835....3425
Event Code 836....3425
Event Code 837....3425
Event Code 838....3425
Brake System....3426
Brake....3428
General....3428
Brake Force Adjustment....3428
Brake Adjustment....3429
Air Gap Adjustment....3429
Torque Gap Adjustment....3430
Rotor and Brake Pad Replacement....3431
Brake Disassembly....3431
Brake Assembly....3431
Brake Troubleshooting....3433
Steering....3434
System Description....3436
Steering Direction....3436
Steering Wheel Direction Indicator....3436
Steering Wheel Adjustment....3437
Steering Motor Gearbox....3438
Lifting Mechanism....3440
General....3442
TT Mast....3442
Shim Basics....3442
Mast Column Roller....3444
Removal....3444
Shim Measurements....3446
Mast Testing (Assembled)....3447
Flaking....3448
Shim Removal....3448
Top Column Rollers....3448
Bottom Column Rollers....3448
Mast....3449
Removal....3449
Assembly....3450
Lift Chains....3451
Inspection....3451
Cleaning....3451
Wear....3451
Freedom of Movement of Chain Links....3452
Chain Tension....3452
Chain Anchor and Pulleys....3453
Worn Connection Plates....3453
Protruding or Turned Chain Pins....3453
Corrosion....3453
Chain Lateral Wear....3454
Uneven Chain Tension....3454
Misaligned Lift Components....3454
Lift Chain Lubrication....3455
Separating Lift Chains....3456
Tools and Equipment Required....3456
Separation....3456
FEM / ISO Forks....3457
General....3457
Terms....3457
Fork Identification....3457
FEM / ISO Fork Inspection....3457
Repair....3457
Inspection Intervals....3457
Crack Inspection....3458
Fork Blade Warping....3458
Fork Tip Straightness Test....3459
Measuring the Fork Tip Height....3459
Fork Tine Height Difference....3459
Fork Stop....3460
Fork Blade Abrasion Check....3460
Platform Fork Blades....3461
General....3461
Table Standard Fork Thickness and Wear Limit....3461
Fork Inspection....3461
Fork Blade Abrasion Check....3461
Overloading....3462
Fatigue....3463
Bent or Twisted Forks....3463
Hanger....3463
Cylinders....3464
Safety....3466
For your personal protection....3466
General Instructions for Repairing Hydraulic Components....3466
Rod Seal Assembly....3467
General....3467
Large Rod Seal Assembly....3467
Small Seal Rod Assembly....3468
Rod Seal Assembly, Sealing Lip First....3469
General....3470
Inspection....3470
Disassembly....3470
Rod Packing....3471
Accessing Mast Cylinder Rod Packing....3471
Accessing Free Lift Cylinder Rod Packing....3471
Rod Packing Replacement (Mast and Free Lift Cylinder)....3471
Mast Cylinder Removal....3473
Free Lift Cylinder Removal....3474
Mast And Free Lift Cylinder Assembly....3475
Mast And Free Lift Cylinder Installation....3475
Bleeding....3475
Platform....3476
Platform....3478
Floor Mat Replacement....3478
Safety Shield....3478
Forks....3479
Fork Inspection....3479
Fork Replacement....3480
Fork Height Adjustment....3480
Pallet Grab (Option)....3481
Release Handle Adjustment....3481
Pedal Adjustment....3481
Pallet Grab Removal....3482
Operator Compartment Gates....3483
Spring Replacement....3483
Removal....3483
Installation....3484
Operator Egress System....3485
Platform Removal & Shimming....3486
Basics....3486
Platform Removal & Shimming....3486
Height Sensor Assembly....3489
Removal....3489
Installation....3490
Encoder (ECR4)....3491
Removal....3491
Installation....3491
Bearing Replacement....3492
Removal....3492
Installation....3492
Cable Replacement....3493
Removal....3493
Installation....3493
Schematic Diagrams....3496
Diagram Usage....3498
Schematic....3498
Pictorials....3498
Index....3499
Block Diagram....3500
Schematic with Options....3501
Schematic without Options....3502
Schematic - SAA....3503
Platform....3504
Platform - SAA....3505
Distribution Panel....3506
Motor Monitoring System MMS....3507
Display Module....3508
Traction Module....3509
Steering Module....3510
Contactor Panel....3511
Guidance Traction....3512
Guidance Module....3513
Lights and Fan....3514
Freezer Conditioning....3515
Freezer Conditioning - SAA....3516
Power Cables....3517
Wire Harnesses....3518
Platform....3518
Power Unit....3519
Hydraulic Schematic....3520
Two Speed Lift....3522
SP3400....3524
Safety....3542
Symbols Used in the Manual....3544
Safety Symbols....3544
General Symbols....3544
Fork direction....3544
General Safety Instructions....3545
Maintenance and Repair Instructions....3545
Maintenance and Repair....3545
Before Parking the Truck....3545
Before Working on the Truck....3545
Before Starting the Truck....3546
Warning and Instruction Decals on the Truck....3546
Control of Hazardous Energy....3548
Battery....3548
Safety Rules....3548
Battery Removal....3549
Battery Installation....3549
Lockout - Tagout....3549
Brake....3550
Capacitance....3551
Hydraulic System....3551
Depressurising the hydraulic system....3551
Accumulator....3552
Lifting and Blocking....3553
Required tools....3553
Raising the Side....3553
Raising the Drive Wheel....3554
Blocking Masts....3555
Cleaning Methods....3556
Introduction....3558
General....3560
Operating Instructions....3560
Service Training....3560
Ordering Spare Parts....3560
Using the Manual....3561
Data Plate....3561
Model Number....3562
* Capacity....3562
** Performance Key....3562
Truck Data Number....3563
Lubrication & Adjustment....3566
General....3568
Charts....3571
Componentry....3581
Accumulator....3581
ALM1 Status Alarm....3581
BRES1, BRES2 (Option) Battery Restraint Switch....3581
BRK1 Brake....3581
BRS1 Brake Switch....3581
CHS1, CHS2 Chain Slack Switches (TT Mast Only)....3583
CHS3, CHS4 Chain Slack Switches....3583
CV1 Check Valve (only 3427 / 3422)....3583
CV2 Check Valve....3583
CV3 Check Valve....3583
Cylinder Free Lift (TT Mast Only)....3583
Cylinder Mast....3583
DCM Display Module....3585
DPS Display Switch....3585
DTS1 Drive / Tow Switch....3585
ECR1 Steering Command Encoder....3585
ECR2 Steering Feedback Encoder....3585
ECR3 Traction Speed Encoder....3585
ECR4 Lift Height Sensor....3585
ED1 Emergency Disconnect Main Contactor....3587
ED2 Emergency Disconnect Traction & Steering Contactor....3587
EDS Emergency Disconnect Switch....3587
Fan Operator Fan....3587
FILTER Return....3587
FNS Fan Switch....3587
FS Forward Switch....3587
FU1 Lights and Fan Fuse....3589
FU2 Control Fuse....3589
FU3 Options Fuse....3589
FU4 Manual Brake Fuse....3589
FU5 Brake Outer Coil Fuse....3589
FU6 Brake Inner Coil Fuse....3589
FU8 Pump Motor 1 Fuse....3589
FU9 Pump Motor 2 Fuse....3589
FU10 Steer Module Fuse....3591
FU11 Freezer Condition Power Unit Fuse....3591
FU12 Freezer Condition Platform Fuse....3591
FU13 Traction Motor Fuse....3591
GCM Guidance Control Module....3591
GTS1, GTS2, GTS3, GTS4 Side Gate Switches....3591
GTS5, GTS6 (SAA Only - not shown) Rear Gate Switches....3591
GUS Guidance Switch....3591
HN1 Horn....3593
HN2 Back-Up or Travel Alarm....3593
HNS1 Horn Switch....3593
HSLCS High Speed Lower Cutout Switch....3593
HSRCS High Speed Raise Cutout Switch....3593
HTS24 610 mm (24 in.) Height Limit Switch....3595
HTS60 1525 mm (60 in.) Height Limit Switch....3595
HTS120 3050 mm (120 in.) Height Limit Switch....3595
HTS150 3810 mm (150 in.) Height Limit Switch....3595
HTS180 4570 mm (180 in.) Height Limit Switch....3597
K1 Power Up Relay....3597
K2 Module Power....3597
K5 Steer Motor Relay....3597
K11 Freezer Condition Relay....3597
K12 Freezer Condition Relay....3597
KYS Key Switch....3599
LCS1 Lower Cutout Switch....3599
LGS1 Dome Light Switch....3599
LGS2 Work Light Switch....3599
LGS3 Spot Light Switch....3599
LGT1 Strobe or Flashing Light....3599
LGT2, 5 Work Lights....3599
LGT3, 6 Dome Lights....3601
LGT4, 7 Spot Lights....3601
LOS1 Low Speed Lower Switch....3601
LOS2 High Speed Lower Switch....3601
M1 Traction Motor....3601
M2 Power Steering Motor....3601
M3 Lift Pump Motor....3601
M4 Lift Pump Motor....3601
MRC1 Traction Module....3603
MVL Manual Valve Lowering....3603
ORS1 Override Switch....3603
P1 Low Speed Lift Pump Contactor....3603
P1 PUMP Low Speed Lift Pump....3603
P2 High Speed Lift Pump Contactor....3603
P2 PUMP High Speed Lift Pump....3603
POT1 Traction Request Potentiometer....3605
PS1 Light Power Supply....3605
PS2 Light Power Supply....3605
PVL Proportional Lowering Valve....3605
RAS1 Low Speed Raise Switch....3605
RAS2 High Speed Raise Switch....3605
RCS1, RCS2 Raise Cutout Switches....3605
RES1 Resistor....3607
RES2, RES3 Freezer Condition Heater....3607
RES4, RES5 Freezer Condition Heater....3607
RES6, RES7 Freezer Condition Heater....3607
RES8, RES9 Freezer Condition Heater....3607
RES10 Freezer Condition Heater....3607
RES11 Freezer Condition Heater....3607
RES12 Freezer Condition Heater....3609
RES13 Freezer Condition Heater....3609
RES14 Freezer Condition Heater....3609
RES15, RES19 Freezer Condition Heater....3609
RES16 Freezer Condition Heater....3609
RES17 Freezer Condition Heater....3609
RES18 Freezer Condition Heater....3609
RES20, RES21 Freezer Condition Heater....3611
RES30 Freezer Condition Heater....3611
RES31 Freezer Condition Heater....3611
RES32 Freezer Condition Heater....3611
Reservoir....3611
RGS1, RGS2 Rail Guide Switches....3611
RS Reverse Switch....3611
RV1 Relief Valve....3611
SB10 Suppressor Block....3613
SB11 Suppressor Block....3613
SB21 Suppressor Block....3613
SB30 Suppressor Block....3613
SCM Steering Control Module....3613
Sensor Bar Load Wheel Wire Guidance....3615
Sensor Bar Steer Wheel Wire Guidance....3615
Strainer Suction....3615
Test Port....3615
THS2 Power Unit Thermostat....3615
THS3 Platform Thermostat....3615
ZSS Zone Select Switch....3615
Skids....3617
Torque Values....3618
Hydraulic System....3620
Hydraulic Symbols....3622
General....3626
Hydraulic Circuits....3627
Lift Circuit - One Speed Lift....3627
Relief Valve Operation....3627
Accumulator Operation....3627
Lift Circuit - Two Speed Lift....3628
Low Speed Lift....3628
High Speed Lift....3628
Relief Valve Operation....3628
Accumulator Operation....3628
Lower Circuit - One Speed/Two Speed Lower....3629
Lower....3629
Manual Lower Circuits....3631
Lift Circuit - One Speed Lift....3634
Lifting Fork Lift Circuit....3634
Relief Valve Operation....3634
Accumulator Operation....3634
Lift Circuit - Two Speed Lift W/Lifting Forks....3637
Low Speed Lift....3637
High Speed Lift....3637
Relief Valve Operation....3637
Accumulator Operation....3637
Lower Circuit - One Speed/Two Speed Lower....3640
Lower....3640
Manual Lower Circuits....3643
Reservoir....3644
Hydraulic Lines and Fittings....3644
Filter....3645
Drift Test....3645
Lift Drift Test....3645
Freezer Preparation....3646
Hydraulic Pump....3647
Pump - Gear....3647
Oil Seal Removal....3647
Oil Seal Replacement....3648
Pump Disassembly....3648
Parts Inspection....3648
Body....3648
Gears....3649
Mounting Flange....3649
Pump Reassembly....3650
Lift/Lower Control Valve....3653
Relief Valve- RV1 Operation....3653
Adjustment (1.25 Trucks)....3653
Relief Valve- RV1 & RV2 Operation....3654
Adjustment (1.0 Trucks)....3654
Accumulator....3656
Precharging....3656
Maintenance....3659
Hydraulics Troubleshooting Chart....3659
Drive Unit....3662
Drive Tire Replacement....3664
Drive Unit Lubrication....3665
Oil Pump Disassembly (Refer to Illustrations 1895 & 13131)....3665
Oil Pump Assembly (Refer to Illustrations 1895 & 13131)....3666
Drive Unit Removal & Installation (Refer to Illustration 3272)....3667
Electrical System....3668
Encoders....3670
Electrical Wiring....3672
Wiring Color Codes....3672
Color....3672
Number....3672
Power Cables....3673
Symbols....3674
Basic Symbols....3675
Motor Monitoring System (MMS)....3677
Overtemperature Sensors....3678
Brushwear Sensors....3678
Event Codes....3680
General....3680
Some Troubleshooting Basics....3680
Check the Event Code Listing....3680
No Event Code?....3680
To Locate Malfunctioning Components....3680
Test Points....3680
Event Codes....3680
Event Code 201....3681
Event Code 202....3682
Event Code 204....3683
Event Code 208....3684
Event Code 209....3686
Event Code 210....3687
Event Code 211....3688
Event Code 212....3689
Event Code 213....3690
Event Code 215....3691
Event Code 216....3693
Event Code 217....3695
Event Code 218....3696
Event Code 219....3697
Event Code 221....3698
Event Code 222....3698
Event Code 223....3699
Event Code 224....3700
Event Code 227....3701
Event Code 228....3702
Event Code 311....3702
Event Code 312....3702
Event Code 313....3703
Event Code 314....3703
Event Code 315....3704
Event Code 316....3705
Event Code 317....3706
Event Code 318....3707
Event Code 319....3708
Event Code 321....3709
Event Code 322....3710
Event Code 323....3711
Event Code 324....3712
Event Code 326....3713
Event Code 327....3713
Event Code 328....3714
Event Code 331....3715
Event Code 332....3717
Event Code 333....3718
Event Code 334....3719
Event Code 335....3720
Event Code 336....3720
Event Code 337....3721
Event Code 339....3722
Event Code 341....3722
Event Code 342....3723
Event Code 343....3723
Event Code 344....3724
Event Code 345....3725
Event Code 346....3726
Event Code 347....3727
Event Code 348....3728
Event Code 349....3729
Event Code 351....3730
Event Code 352....3731
Event Code 353....3732
Event Code 354....3733
Event Code 355....3733
Event Code 356....3733
Event Code 357....3734
Event Code 358....3734
Event Code 362....3734
Event Code 363....3735
Event Code 364....3736
Event Code 365....3737
Event Code 366....3737
Event Code 367....3738
Event Code 368....3738
Event Code 369....3738
Event Code 371....3739
Event Code 372....3739
Event Code 373....3739
Event Code 374....3740
Event Code 375....3740
Event Code 376....3740
Event Code 377....3741
Event Code 378....3741
Event Code 379....3742
Event Code 381....3742
Event Code 382....3742
Event Code 383....3743
Event Code 384....3744
Event Code 385....3745
Event Code 386....3745
Event Code 387....3745
Event Code 388....3746
Event Code 391....3746
Event Code 392....3746
Event Code 393....3746
Event Code 394....3747
Event Code 396....3748
Event Code 397....3749
Event Code 398....3749
Event Code 399....3749
Event Code 411....3749
Event Code 412....3749
Event Code 413....3749
Event Code 414....3750
Event Code 415....3750
Event Code 416....3750
Event Code 417....3750
Event Code 418....3750
Event Code 419....3751
Event Code 421....3752
Event Code 422....3755
Event Code 423....3757
Event Code 424....3759
Event Code 425....3760
Event Code 426....3762
Event Code 427....3762
Event Code 428....3764
Event Code 429....3766
Event Code 431....3766
Event Code 432....3766
Event Code 433....3766
Event Code 434....3767
Event Code 435....3767
Event Code 436....3767
Event Code 437....3767
Event Code 438....3768
Event Code 439....3768
Event Code 441....3770
Event Code 442....3772
If: Fault persists. Then replace GCM....3773
Event Code 800....3773
Event Code 801....3773
Event Code 802....3774
Event Code 803....3775
Event Code 804....3776
Event Code 805....3776
Event Code 806....3777
Event Code 807....3778
Event Code 808....3779
Event Code 809....3780
Event Code 810....3781
Event Code 811....3781
Event Code 812....3782
Event Code 813....3782
Event Code 814....3782
Event Code 827....3783
Event Code 828....3784
Event Code 829....3785
Event Code 831....3787
Event Code 832....3789
Event Code 833....3790
Event Code 834....3790
Event Code 835....3790
Event Code 836....3790
Event Code 837....3791
Event Code 838....3791
Tune Up....3792
Service Terminal....3792
Description....3792
Service Terminal Operation....3793
Keyboard Commands....3793
Calibration....3795
Truck Setup Menus....3796
Lift Cutouts or Zone Menus....3797
Truck Option Menus....3798
P.M. Interval Setup Menus....3799
Hourmeter Reset Menus....3800
Wire Guidance Calibration Menus....3801
Traction Setups/Calibration Menus....3802
Traction Setups/Features Menus....3803
Features/Travel Alarm Menus....3804
Traction Setups/Performance Menus....3805
Traction Setups/Performance Menus (cont'd)....3806
System Information Menus....3811
View Enable Config Menus....3812
Truck Monitors Menus / View Encoder Counts Menu....3813
View Switch Status Menus / View System Constants Menus....3814
View Hardware Outputs Menus....3816
View Hourmeter Data Menus / View Wire Guide Sensors Menus....3817
Traction Analyzer Menus....3818
Status Analyzer Menus....3819
Traction Inputs Menus....3820
View Switches Menu....3821
Traction Outputs Menus....3822
Wire Guidance System....3823
Operation Modes....3824
Manual....3824
Automatic....3824
Sensors....3826
Calibration....3826
Troubleshooting....3827
Guidance Module (GCM)....3828
Pin assignment....3828
Line Driver Output.....3830
Sensor Bearing....3832
Checking Truck Steering System....3833
Truck Steering System Components....3834
Contactors....3836
Inspection....3836
Contacts....3836
Coil....3836
Component Replacement....3837
Contact Replacement....3837
Coil Replacement....3837
Steering Feedback....3838
Gear Assembly....3838
4.5-7534....3843
4.5-7534....3841
Control Module....3840
General....3840
Access....3840
Troubleshooting....3841
Adjustment....3841
Acceleration Potentiometer (POT1)s....3841
Directional Switches (FS & RS)....3842
Component Replacement....3843
FS and RS....3843
Actuator Arm....3843
Potentiometer (POT1)....3844
Cam Torsion Spring, Stop....3845
Twist Grip....3846
RAS1, RAS2, LOS1, LOS2, HNS, EDS....3847
Button Return Springs....3847
Buttons....3847
Power Disconnect Button Springs....3848
Notes:....3849
4.5-7534....3845
4.5-7534....3847
Battery....3850
Safety Rules....3850
Checking....3851
Battery Care....3851
Charging....3852
Placing battery on charge:....3853
Removing battery from charge:....3853
Battery Stop Adjustment....3853
Battery Removal....3854
Battery Installation....3855
Battery Cleaning....3856
Trouble Shooting....3856
Motors....3857
Brake System....3860
General....3862
Braking Force....3862
Brake Force Adjustment....3862
BRAKE ADJUSTMENT....3863
Air Gap Adjustment....3863
Torque Gap Adjustment....3864
Rotor and Brake Pad Replacement....3866
Brake Assembly....3867
Steering....3870
System Description....3872
Steering Direction....3872
Steering Wheel Direction Indicator....3872
Steering Wheel Adjustment....3873
Steering Motor Gearbox....3874
Lifting Mechanism....3876
Lift Chains....3878
Inspection....3878
Cleaning....3878
Wear....3878
Freedom of Movement of Chain Links....3880
Chain Tension....3880
Chain Anchor and Pulleys....3880
Worn Connection Plates....3880
Protruding or Turned Chain Pins....3881
Corrosion....3881
Chain Lateral Wear....3881
Uneven Chain Tension....3882
Misaligned Lift Components....3882
Lift Chain Lubrication....3882
Separating Lift Chains....3884
Tools and Equipment Required....3884
Separation....3884
FEM / ISO Forks....3886
General....3886
Terms....3886
Fork Identification....3886
FEM / ISO Fork Inspection....3887
Repair....3887
Inspection Intervals....3887
Crack Inspection....3887
Fork Blade Warping....3887
Fork Tip Straightness Test....3888
Measuring the Fork Tip Height....3888
Fork Tine Height Difference....3888
Fork Stop....3889
Fork Blade Abrasion Check....3889
Platform Fork Blades....3890
Fork Inspection....3890
Fork Blade Abrasion Check....3890
Overloading....3892
Bent or Twisted Forks....3892
Hanger....3893
Cylinders....3894
Safety....3896
For your personal protection:....3896
General Instructions for Repairing Hydraulic Components....3896
Rod Seal Assembly....3897
General....3897
Large Rod Seal Assembly....3897
Small Seal Rod Assembly....3898
Rod Seal Assembly, Sealing Lip First....3899
Maintenance....3900
Mast, Free Lift and Auxiliary Fork Cylinders....3900
Inspection....3901
Disassembly....3902
Accessing Rod Packing- Mast Cylinder....3902
Accessing Rod Packing - Free Lift Cylinder....3903
Accessing Rod Packing- Auxiliary Fork Cylinder....3903
Rod Packing Replacement....3903
Mast Cylinder Removal....3905
Auxiliary Fork Cylinder Removal....3906
Free Lift Cylinder Removal....3906
Free Lift, Mast and Auxiliary Fork Cylinder Assembly....3907
Free Lift, Mast and Auxiliary Fork Cylinder Installation....3907
Platform....3908
Safety Shield Installation....3910
Floor Mat Replacement....3911
Forks....3911
Fork Inspection....3911
Fork Replacement....3912
Removal....3912
Installation....3912
Pallet Grab (Option)....3913
Release Handle Adjustment....3913
Pedal Adjustment....3913
Pallet Grab Removal....3914
Operator Compartment Gates....3916
Spring Replacement....3917
Removal....3917
Installation....3917
Operator Egress System....3918
Platform Removal & Shimming....3918
Basics....3918
Platform Removal and Shimming, TL Mast....3919
Shimming....3919
Removing the Platform for Shimming....3919
Correct Method Shimming Method....3921
Incorrect Shimming Method....3921
Installing the Platform....3921
Platform Removal & Shimming TT Mast....3922
Removing the Platform for Shimming....3923
Correct Method Shimming Method....3924
Incorrect Shimming Method....3924
Installing the Platform....3924
Electrical Components....3926
Index....3928
Schematic Diagrams....3938
Block Diagram....3940
Schematic, Standard....3941
Schematic with Options....3942
Platform, Standard....3943
Platform, Auxiliary Fork Lift....3944
Distribution Panel....3945
Traction, Standard....3946
Traction, Auxiliary Fork Lift....3947
Display Module (DCM)....3948
Traction Module (MRC1)....3949
Steering Module (SCM)....3950
Traction Control....3951
Guidance Control Module (GCM)....3952
Lights, Fan, Power Supply....3953
Freezer Condition....3954
Power Cables....3955
Order Information....3956
Wire Harness....3957
Platform....3957
Power Unit....3957
Power Unit....3959
Platform....3960
Platform with Auxiliary Lift Fork....3961
Hydraulic Schematic....3962
Single Speed Lift....3964
Two Speed Lift....3965
Single Speed Lift With Lifting Forks....3966
Two Speed Lift With Lifting Forks....3967
TL Mast....3968
TT Mast....3969
ST3000....3970
ST3000....3971
ST3000 Series....3971
Overview of Revisions....3973
TABLE OF CONTENT....3977
SAFETY....3987
Safety Symbols used in the Manual....3987
General Maintenance and Repair Safety Notes....3987
Maintenance and Repair....3987
Before Leaving the Truck....3988
Before Carrying out Work on the Truck....3988
Before Operating the Truck....3988
Warnings and Labels on the Truck....3988
INTRODUCTION....3991
General....3991
Operating Instructions....3991
Service Training....3991
Ordering Spare Parts....3991
Using the Manual....3991
Model-Number....3992
LUBRIFICATION AND ADJUSTMENT....3995
COMPONENT ACCESS....3995
Lifting and Blocking....3997
Outriggers....3998
Recommended Lubricants and Oils....3999
Cold Store Trucks....3999
Truck Decommissioning....3999
Restoring the Truck to Service....3999
Maintenance....4003
Lubrication points and intervals....4003
Inspection and Maintenance Schedule....4005
Casters....4014
Torques....4015
HYDRAULICS....4019
Hydraulic Symbols....4019
Hydraulic Unit Removal....4023
Hydraulic System....4024
Operation....4024
Raise....4024
Lower....4025
Hydraulic Reservoir Capacity....4026
Changing the hydraulic oil and hydraulic filter....4026
MOTOR & PUMP ASSEMBLY....4028
HYDRAULIC LINES AND FITTINGS....4028
General Rules for Hydraulic Lines and Fittings....4028
CIRCUIT BLEEDING....4029
DRIFT TEST....4029
REMOVAL....4029
MOTOR....4030
PUMP....4030
Replacing the relief valve....4031
Relief valve setting....4031
Relief valve test and setting....4031
HYDRAULIC TROUBLESHOOTING CHART....4032
DRIVE UNIT....4035
Gear Unit....4035
Drive unit, general....4036
Drive unit removal....4036
Drive motor removal....4036
Motor disassembly....4037
Motor assembly....4037
Gear unit disassembly....4040
General....4040
Preparation....4040
Draining the oil....4040
Drive unit removal....4040
Gear unit cover removal....4040
Gear unit assembly....4041
Gear unit cover installation....4043
Adding Oil....4043
Drive unit installation....4043
ELECTRICS....4047
Electrics - General....4047
Wire Colour Codes....4047
Abbreviations....4048
Electrical Symbols....4051
Electrical Components....4052
Traction Pod (POT, FS, RS)....4052
Fast / Slow Travel Switch (HSS)....4052
Safety Reverse Switch (SAS)....4052
Brake Switch (BRS)....4052
Override Switch (ORS)....4052
Raise / Lower Switches (RAS, LOS)....4053
Limit Switch (LMS)....4053
Horn Switch (HNS)....4053
Key Switch (KYS)....4053
Emergency Disconnect (BD)....4053
Fuses (FU)....4053
Thermal Switch (THS)....4053
Hydraulic Control Module (HCM)....4053
Unigage (BDI)....4053
Integrated Charger....4053
Plug Holder (PC)....4053
Drive motor (M1)....4053
Hydraulic Motor (M2)....4053
Main Contactor (Line/LC)....4054
Lift Contactor (P/P1+P2)....4054
Electromagnetic Brake (BRK)....4054
Terminal Board (TB)....4054
Travel Alarm Driver (DR)....4054
Aux. Hydraulic Switch (SLS/SRS)....4054
Remote Control Toggle Switch (ECS)....4054
Aux. Hydraulic Valves (SVA1/SVA2)....4054
Horn (HN)....4054
Main Circuit Board (MAIN PCB)....4054
Hydraulic Circuit Board (HYD PCB)....4054
Travel Alarm (ALM)....4054
Receiver....4054
Transmitter....4054
SEM0 Traction Controller....4058
General....4058
Maintenance....4060
Replacing the SEM0 Traction Controller....4061
Parameter Setting after Replacing the Traction Controller....4061
Status LED....4063
Programmer....4064
Operating SEM0 Controller Menu....4065
Menu structure....4065
Menu Functions....4066
Functions Menu, general....4067
Parameter Change Menus....4068
Settings and Error Messages....4069
Tester Menu....4070
TESTER Menu....4071
Alarms Menu....4072
ALARMS Menu....4073
Calibrating the Traction Pod....4076
Config. Menu....4077
CONFIG Menu....4078
On Board Charger....4079
Charging Errors....4081
Important Technical Data....4082
Replacing the Charger....4082
Traction Motor Maintenance....4083
Pump Motor Maintenance....4084
Contactors....4086
Hydraulic Control Module (HCM)....4088
Battery Discharge Indicator (BDI)....4089
Battery Discharge Indicator Setting....4090
Calibration for wet batteries....4091
TROUBLESHOOTING....4092
Traction Controller Safety Test....4093
BRAKE....4097
Air gap setting....4099
Brake moment setting....4100
Brake test....4100
Definition of run-in/new rotor....4100
Troubleshooting....4101
STEERING....4105
Live ring bearing....4105
Control handle return springs....4106
Control Handle Grip....4107
MAST....4119
Torque Requirements....4119
Lifting Gear Minimum Capacity....4119
Mast Removal....4119
Installation....4120
Fork Carriage Removal....4120
Fork Carriage Installation....4121
Fork Carriage Adjustment....4121
Mast Maintenance....4122
Lift chains....4126
Fork Tines....4132
CYLINDERS....4137
Rod Seal Assembly....4138
Mast Lift Cylinder....4141
Carriage Cylinder....4143
Cylinder Bleeding and Flushing....4144
Drift Test....4145
Cylinder Shimming....4145
ELECTRICAL DIAGRAMS....4147
Terms....4166
HYDRAULIC CIRCUIT....4169
SX3000....4171
SX3000....4172
SX3000....4172
Overview of Revisions....4174
Table of Contents....4178
SAFETY....4188
Safety Symbols used in the Manual....4188
General Maintenance and Repair Safety Notes....4188
INTRODUCTION....4190
General....4192
Operating Instructions....4192
Service Training....4192
Ordering Spare Parts....4192
Using the Manual....4192
Model-Number....4193
LUBRICATION AND ADJUSTMENT....4196
COMPONENT ACCESS....4196
Lifting and Blocking....4198
Outriggers....4199
Recommended Lubricants and Oils....4200
Truck Decommissioning....4200
Restoring the Truck to Service....4200
Maintenance....4204
Lubrication points and intervals....4204
Inspection and Maintenance Schedule....4206
Casters....4215
Torques....4216
HYDRAULICS....4220
Hydraulic Symbols....4220
Hydraulic Unit Removal....4224
Hydraulic System....4225
Operation....4225
Hydraulic Reservoir Capacity....4227
Changing the hydraulic oil and hydraulic filter....4227
MOTOR & PUMP ASSEMBLY....4229
HYDRAULIC LINES AND FITTINGS....4229
General Rules for Hydraulic Lines and Fittings....4229
CIRCUIT BLEEDING....4230
DRIFT TEST....4230
REMOVAL....4230
MOTOR....4231
PUMP....4231
Replacing the relief valve....4232
Relief valve setting....4232
Relief valve test and setting....4232
DRIVE UNIT....4236
Drive unit, general....4237
Drive unit removal....4237
Drive motor removal....4237
Motor disassembly....4238
Motor assembly....4238
Drive motor assembly....4240
Gear unit disassembly....4241
General....4241
Preparation....4241
Draining the oil....4241
Drive unit removal....4241
Gear unit cover removal....4241
Gear unit disassembly....4242
Gear unit assembly....4242
Gear unit cover installation....4244
Adding Oil....4244
Drive unit installation....4244
ELECTRICS....4248
Electrics - General....4248
Wire Colour Codes....4248
Abbreviations....4249
Electrical Symbols....4252
Electrical Components....4253
SEM0 Traction Controller....4259
General....4259
Functional Characteristics....4259
Safety Mechanisms....4260
Maintenance....4261
Replacing the SEM0 Traction Controller....4262
Parameter Setting after Replacing the Traction Controller....4262
Status LED....4264
Programmer....4265
Operating SEM0 Controller Menu....4266
Menu structure....4266
Menu Functions....4267
Functions Menu, general....4268
Parameter Change Menus....4269
Settings and Error Messages....4270
Tester Menu....4271
TESTER Menu....4272
Alarms Menu....4273
ALARMS Menu....4274
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu....4277
Config. Menu....4278
CONFIG Menu....4279
On Board Charger....4280
Battery Charging Phases....4280
Special Charging Phases....4281
Charging Errors....4282
Important Technical Data....4283
Replacing the Charger....4283
Electric Motors....4284
Traction Motor Maintenance....4285
Pump Motor Maintenance....4286
Contactors....4287
Inspection....4287
Servicing....4288
Hydraulic Control Module (HCM)....4289
Battery Discharge Indicator (BDI)....4290
OPERATION....4290
Battery Discharge Indicator Setting....4291
Calibration for wet batteries....4292
TROUBLESHOOTING....4293
Traction Controller Safety Test....4294
BRAKE....4298
Disassembly....4298
Assembly....4300
Brake moment setting....4301
Brake test....4301
Definition of run-in/new rotor....4301
Troubleshooting....4302
STEERING....4306
Live ring bearing....4306
Disassembly....4306
Assembly....4306
Control handle return springs....4307
Adjustment....4307
Disassembly....4307
Assembly....4307
Control Handle Grip....4308
Main Components....4308
Hand grip component removal and assembly....4309
MAST....4320
Torque Requirements....4320
Lifting Gear Minimum Capacity....4320
Mast Removal....4320
Installation....4321
Fork Carriage Removal....4321
Fork Carriage Installation....4322
Fork Carriage Adjustment....4322
Mast Maintenance....4323
Mast shims....4324
TL Mast Assembly....4325
TT Mast Assembly....4326
Lift chains....4327
Inspection....4327
Cleaning....4327
Wear....4327
Freedom of Movement of Chain Links....4328
Chain Tension....4328
Chain Anchor and Pulleys....4329
Worn Connection Plates....4329
Protruding or Turned Chain Pins....4329
Corrosion....4329
Chain Lateral Wear....4330
Lift Chain Lubrication....4331
Separating Lift Chains....4332
Fork Tines....4333
Repairs....4333
Fork Inspection....4333
CYLINDERS....4338
Rod Seal Assembly....4339
Mast Lift Cylinder....4342
Carriage Cylinder....4344
Cylinder Bleeding and Flushing....4345
Drift Test....4346
Cylinder Shimming....4346
ELECTRICAL DIAGRAMS....4348
SX 3000 Standard....4350
Overview....4350
Traction Controller - Sem0 Logic....4351
Traction Controller - Sem0 Power Circuit....4352
Power Unit Control Circuit....4353
Control Handle - Control Circuit....4354
Hydraulic Control Module (HCM)....4355
SX 3000 with Options....4356
Overview....4356
Traction Controller - Sem0 Logic....4357
Traction Controller - Sem0 Power Circuit....4358
Power Unit - Control Circuit....4359
Control Handle - Control Circuit....4360
Hydraulic Control Module (HCM) - Travel Alarm and Flashing Beacon....4361
Wire Harness....4362
Control Handle Wiring....4363
Power Cables....4364
Terms....4365
HYDRAULIC DIAGRAMS....4368
SX 3000 Standard....4368
SX3000 with Sideshift....4369
TSP6000....4370
TSP6000....4371
Safety....4393
Symbols Used in the Manual....4395
Safety Symbols....4395
General Symbols....4395
Fork direction....4395
General Safety Instructions....4396
Maintenance and Repair Instructions....4396
Maintenance and Repair....4396
Before Parking the Truck....4396
Before Working on the Truck....4396
Before Starting the Truck....4396
Warning and Instruction Decals on the Truck....4397
Control of Hazardous Energy....4398
Battery....4398
Safety Rules....4398
Battery Care....4398
Charging....4398
Battery Removal....4398
Battery Installation....4399
Lockout - Tagout....4399
Brake....4400
Capacitance....4400
Hydraulic....4401
Depressurizing the Hydraulic System....4401
Lifting and Blocking....4402
Lifting one Side....4402
Lifting the Steered Wheel....4403
Masts....4403
Blocking Main Mast....4403
Blocking Auxiliary Mast....4404
Height Sensor....4405
Spring Removal....4405
Spring Installation....4406
Lifting Auxiliary Mast and Platform....4407
Auxiliary Mast....4407
Platform....4407
Service Platform....4408
Cleaning Methods....4409
Introduction....4411
General....4413
Operating Instructions....4413
Service Training....4413
Ordering Spare Parts....4413
Using the Manual....4413
Truck Data Number....4414
Table Lift Heights....4415
Table Guide Wheel Spreads....4415
Lubrication & Adjustment....4417
General....4419
Lube Identification....4419
Alternate Lube Identification....4421
General....4423
Safety....4423
Maintenance Intervalls....4423
Component Accessibility....4423
Maintenance Intervalls....4424
Charts Part 1....4425
Charts Part 2....4426
Charts Part 3....4429
Charts Part 4....4431
Componentry....4432
ACM (Access 7)....4432
ALM1....4432
ALM2 (Optional)....4432
BRK....4432
BRS1, BRS2, BRS3, BRS4....4432
CHS1, CHS2....4432
CHS3, CHS4....4434
CS1....4434
CTS (TF Mast Only)....4436
DCM (Access 1)....4436
DTS....4436
EACA1....4436
EACA2....4436
EACB1....4436
EACB2....4436
ECR1....4438
ECR2....4438
ECR3....4438
ECR4....4438
ECR5....4438
ECR6....4438
ECR7....4438
ECR8....4438
ED1, ED2....4440
EDS....4440
EML....4440
EMS1....4440
FAN1....4440
FAN3 (Option)....4440
FHSL, FHSR....4440
FNS....4440
FPS1, FPS2, FPS3, FPS4, FPS5, FPS6, FPS7, FPS8, FPS9....4442
FS....4442
FSB1....4442
FSB2....4442
FU1....4442
FU2....4442
FU3....4444
FU4....4444
FU5....4444
FU6....4446
FU7....4446
FU8....4446
FU9....4446
FU10....4446
FU11....4446
FU12....4446
FU13....4446
FU14....4448
FU15....4448
FU16....4448
FU17....4448
FU18....4448
FU19....4448
FU20....4448
FU21....4448
FU22....4450
FU23....4450
GCM (Access 6) (Optional)....4450
GS1....4450
GS2....4450
GTSL, GTSR....4450
GUS....4450
HCM (Access 2)....4452
HCS....4454
HGTRS1....4454
HGTRS2....4454
HN....4454
HNS....4454
HPSL....4454
HPSR....4454
K1....4456
K2....4456
KYS....4456
LGS1....4456
LGS2....4456
LGS3....4456
LGT1....4456
LGT2, 3....4456
LGT4, 5....4458
LGT6, 7....4458
LGT8, 9....4458
LS....4458
M1....4458
M2....4458
M3....4458
MVL....4458
OCM (Access 8)....4460
ORS1....4460
P1....4460
PCML....4460
PLS....4460
POT1....4460
POT2....4460
Main Hoist Raise/LowerPOT3....4460
Pot3....4460
POT4....4462
POT5....4462
PRS....4462
PS1....4462
PS2....4462
PVAL....4462
PVAR....4462
PVF - S1....4464
PVF - S2....4464
PVLH....4466
PVMR....4466
PVP....4466
PVT....4466
RES1, RES2....4466
RES3....4466
RES4....4466
RES5....4466
Reservoir....4468
RGSL, RGSR (Optional)....4468
RS....4468
RSS....4468
SB11....4468
SB31....4468
SCM (Access 5)....4468
SES....4468
SLS....4470
SP1....4470
SPS....4470
SVAL....4470
SVML....4470
TBS (Optional)....4470
TCM (Access 3)....4470
TDS (Optional)....4470
TS1....4472
TS2....4472
TS3....4472
TS4....4472
TVRS....4472
VCM (Access 4)....4472
ZSS....4472
Hydraulic System....4475
Hydraulic Symbols....4477
General....4481
Hydraulic Lines and Fittings....4481
Freezer Preparation....4481
Reservoir & Filter....4482
General....4482
Drift Test....4482
Main Lift Circuit....4483
Main Lower Circuit....4484
Main Lower Circuit (MVL)....4485
Load Handler Circuit through Main Frame Manifold....4486
Auxiliary Lift Circuit....4488
Auxiliary Lower Circuit....4490
Traverse Left Circuit....4491
Traverse Right Circuit....4493
Fork Extend Circuit....4495
Fork Retract Circuit....4497
Pivot Right Circuit....4499
Pivot Left Circuit....4501
Hydraulic Pump....4503
Pump Removal....4503
Initial Start Up Procedure....4504
Valves....4505
Relief Valve (RV1)....4505
Adjustment....4505
Proportional Valves....4505
Manifold Block....4506
O-Ring Replacement....4506
Valve Torque Charts....4507
Main Frame Manifold....4507
Load Handler Manifold....4510
Hydraulic Motor....4513
Preparation Before Disassembly....4513
Tools and Materials Required for Servicing....4513
Disassembly and Inspection....4516
Reassembly....4521
Final Checks....4527
Trouble Shooting Table....4528
Drive Unit....4529
Drive Tyre....4531
Replacement....4531
Lathe Cutting....4532
Lubrication....4533
Removal / Installation....4534
Removal....4534
Installation....4534
Motor Removal / Installation....4535
Removal....4535
Installation....4535
Electrical System....4537
Tune Up....4539
Display (Access 1)....4539
When a Malfunction Occurs....4539
Accessing Event History....4539
Power Cable Connections....4539
Access Modules....4540
Main Menu....4542
A - Analyzer Menu....4543
A1.1 - Status Menu....4544
A2 - Inputs....4545
A2.1. - Load Handler....4546
A2.1. - Load Handler....4547
A2.2 - Platform Menu....4548
A2.3. - Seat Controls Menu....4549
A2.4. - Power Unit Menu....4550
A2.4. - Power Unit Menu....4551
A2.4. - Power Unit Menu....4552
A3 - Outputs....4553
A3.1 - Load Handler....4554
A3.1 - Load Handler....4555
A3.1 - Load Handler....4556
A3.1 - Load Handler....4557
A3.1 - Load Handler....4558
A3.2 - Platform Menu....4559
A3.3 - Seat Controls Menu....4560
A3.4 - Power Unit Menu....4561
A3.4 - Power Unit Menu....4562
A3.4 - Power Unit Menu....4563
A3.4 - Power Unit Menu....4564
A3.4 - Power Unit Menu....4565
A4 - Test Outputs Menu....4566
A4.1 - Load Handler Menu....4567
A4.1 - Load Handler Menu....4568
A4.2 - Platform Menu....4569
A4.3 - Seat Controls Menu....4570
A4.4 - Power Unit Menu....4571
A4.4 - Power Unit Menu....4572
A4.5 - Power Unit Menu....4573
C - Calibrations Menu....4574
C1 - Handles Menu....4575
C1 - Handles Menu....4576
C2 - Hydraulics Menu....4577
C2.1 - Traverse Sense....4578
C2.2 - Pivot Sense....4579
C2.3 - Main R Valve....4580
C2.4 - Main L Valve....4581
C2.5 - Main Height Sense....4582
C2.6 - Aux Flow Valve....4583
C2.7 - Traverse Valve....4584
C2.8 - Pivot Valve....4585
C2.9 - Extend Valve....4586
C2.10 - Aux R Valve....4587
C2.11 - Weight Sense....4588
C2.12 - Aux L Valve....4589
C2.13 - Aux Height Sense....4590
C2.14 - Tilt Valve....4591
C3 - Height Cutouts....4592
C4 - Steer Encoder....4593
C5 - Wire Guide....4594
C5.1 - Calibrate....4595
C5.1 - Calibrate....4596
C5.1 - Calibrate....4597
C5.1 - Calibrate....4598
C5.2 - Ajust X-Offset....4599
C5.2 - Ajust X-Offset....4600
F - Features Menu....4601
F1 - Truck Model....4602
F2 - Mast Type....4602
F3 - Measurement....4603
F4 - F6 Collapsed Height, Height & Traverse Menus....4604
F7 - Fork Type....4605
F7 - Fork Type....4606
F8, F10, F11: Fork Length, Pallet Width, Pallet Length....4607
F12 - Battery Compartment....4608
F13 - F14 Truck Weight, Max. Load....4609
F15 - Lift Motor....4610
F16 - Capacity Data Monitor....4612
F17 - Wire Guidance....4614
F18 - Manual Wire Sense....4615
F19 - End Aisle Sense....4616
F20 - Battery Retainer SW....4617
F21 - Travel Alarm....4618
F23 - Language....4619
F24 - User Performance....4620
F25 - User Codes....4621
F26 - Cold Condition....4622
F27 - Options....4623
F27 - Options....4624
F28 - Front Rail....4625
F29 - Zone Switch....4625
F30 - Aux. Mast....4626
F31 - Screen Setup....4626
F99 - Save....4627
H - Hour Meter Menu....4628
H1 - H12 Hour Meters....4628
L - Event Codes Menu....4629
L1 - L3 Event Codes....4629
P - Performance Menu....4630
P1 - Setup P1....4631
P1 - Setup P1....4632
P1 - Setup P1....4633
P2 - Setup P2....4634
P2 - Setup P2....4635
P3 - Setup P3....4636
P3 - Setup P3....4637
P4 - Plug....4638
P5 - Coast....4638
P6 - Braking....4639
P7 - Free Range Speeds....4640
P8 - Guided Speeds....4641
P9 - BDI....4641
P10 - EAC Setup....4642
P10 - EAC Setup....4643
P11- Main Hoist R/L....4644
P11- Main Hoist R/L....4645
P12- Aux. Hoist R/L....4646
P13- PDS Setup....4647
P13- PDS Setup....4648
U - Utilities Menu....4649
U1 - Part Numbers....4650
U2 - Tow Mode....4651
U3 - Shipping Mode....4651
U4 - Truck Lockout....4651
U5 - Traverse Valve....4653
Wire Guidance System....4655
Operation Modes....4656
Manual....4656
Automatic....4656
Sensors....4657
Line Driver Output....4658
Calibration....4659
End of Aisle Control (EAC)....4660
Wire Guidance Calibration Speed....4661
Peak sensor wire guidance calibration....4661
Offset wire guidance calibration....4661
EAC Zones....4661
Troubleshooting....4661
Termination Point Locations....4662
Contactors....4663
General....4663
ED1 Contactor....4663
Inspection....4663
Contacts....4663
Coil....4663
Component Replacement....4663
Contact Replacement....4663
Coil Replacement....4663
Contactor K2....4664
Battery....4665
Location....4665
General Safety Rules....4665
Maintenance and Repair....4665
Replacing the Battery....4665
Charging....4666
General Charging Safety Rules....4666
Motors....4668
Event Codes, General....4669
Troubleshooting Basics....4669
When a Malfunction Occurs....4669
No Event Code?....4669
To Locate Malfunctioning Components....4669
Test Points....4669
Power Cable Connections....4669
Access Modules....4670
Eventcode 101....4671
Eventcode 104....4672
Eventcode 105....4673
Event Code 106....4674
Event Code 107....4675
Event Code 108....4676
Event Code 112 - 118....4677
Event Code 112....4677
Event Code 113....4677
Event Code 114....4677
Event Code 115....4677
Event Code 116....4677
Event Code 117....4677
Event Code 118....4677
Event Code 212 - 214....4678
Event Code 212....4678
Event Code 213....4678
Event Code 214....4678
Event Code 215 - 217....4679
Event Code 215....4679
Event Code 216....4679
Event Code 218, 221- 222....4680
Event Code 218....4680
Event Code 221....4680
Event Code 222....4680
Event Code 223 - 224....4681
Event Code 224....4681
Event Code 225, 228....4682
Event Code 225....4682
Event Code 229, 231....4683
Event Code 229....4683
Event Code 231....4683
Event Code 232....4685
Event Code 233....4687
Event Code 234....4689
Event Code 235....4690
Event Code 236, 237, 246, 247....4692
Event Code 236....4692
Event Code 237....4692
Event Code 246....4692
Event Code 247....4692
Event Code 249, 251, 268 - 269....4693
Event Code 249....4693
Event Code 250....4693
Event Code 268....4693
Event Code 269....4693
Event Code 272....4694
Event Code 273, 278....4695
Event Code 273....4695
Event Code 278....4695
Event Code 300, 312 - 313, 315....4696
Event Code 300....4696
Event Code 312....4696
Event Code 313....4696
Event Code 315....4696
Event Code 317 or 318....4697
Event Code 321, 322....4698
Event Code 321....4698
Event Code 322....4698
Event Code 323 or 324....4699
Event Code 325....4700
Event Code 326 and 327....4701
Event Code 326....4701
Event Code 327....4701
Event Code 328 - 329....4702
Event Code 328....4702
Event Code 329....4702
Event Code 331 - 332....4703
Event Code 331....4703
Event Code 332....4703
Event Code 333....4704
Eventc Code 334....4705
Event Code 336....4706
Event Code 337, 346, 347, 349, 351, 368....4707
Event Code 337....4707
Event Code 346....4707
Event Code 347....4707
Event Code 349....4707
Event Code 351....4707
Event Code 368....4707
Event Code 369....4708
Event Code 372....4709
Event Code 373, 378....4710
Event Code 378....4710
Event Code 400....4711
Event Code 402....4713
Event Code 403....4715
Event Code 407....4716
Event Code 408 & 409....4717
Event Code 411 - 430, 436....4718
Event Code 411 - 430....4718
Event Code 436....4718
Event Code 437 - 438....4719
Event Code 437....4719
Event Code 438....4719
Event Code 439 - 440....4720
Event Code 439....4720
Event Code 440....4720
Event Code 441....4721
Event Code 442 - 443....4722
Event Code 442....4722
Event Code 443....4722
Event Code 444....4723
Event Code 445....4724
Event Code 446....4725
Event Code 447, 491 - 499....4726
Event Code 447....4726
Event Code 491 - 499....4726
Event Code 501....4727
Event Code 502 - 503....4729
Event Code 502....4729
Event Code 503....4729
Event Code 504 - 505....4730
Event Code 504....4730
Event Code 505....4730
Event Code 507....4731
Event Code 508....4732
Event Code 509 & 510, 511 - 521....4733
Event Code 509 & 510....4733
Event Code 511 - 521....4733
Event Code 522 & 523....4734
Event Code 524 - 527....4735
Event Code 526 & 527....4735
Event Code 528 & 529....4736
Event Code 530 & 531....4737
Event Code 532 & 533....4738
Event Code 534 & 535, 536....4739
Event Code 534 & 535....4739
Event Code 536....4739
Event Code 537 - 539....4740
Event Code 538 & 539....4740
Event Code 540....4741
Event Code 541....4742
Event Code 542 - 545....4744
Event Code 542....4744
Event Code 544....4744
Event Code 545....4744
Event Code 546 - 550....4745
Event Code 551 - 554....4746
Event Code 551....4746
Event Code 552 & 553....4746
Event Code 554....4746
Event Code 555 & 556....4747
Event Code 557....4748
Event Code 558 - 561....4749
Event Code 562 - 564....4750
Event Code 562....4750
Event Code 563....4750
Event Code 564....4750
Event Code 565....4751
Event Code 566, 567 - 570....4752
Event Code 566....4752
Event Code 567 - 570....4752
Event Code 571 & 572, 573 - 581....4754
Event Code 571 & 572....4754
Event Code 573 - 581....4754
Event Code 582 - 585....4755
Event Code 586 & 587....4756
Event Code 588 & 589....4757
Event Code 590 - 593....4758
Event Code 590 & 591....4758
Event Code 592 & 593....4758
Event Code 594, 595....4759
Event Code 595....4759
Event Code 596....4760
Event Code 597....4761
Event Code 605, 611 & 612, 621 - 628, 631....4762
Event Code 605....4762
Event Code 611 & 612, 621 - 628....4762
Event Code 631....4762
Event Code 632....4763
Event Code 633....4764
Event Code 636, 637....4765
Event Code 636....4765
Event Code 637....4765
Event Code 638 & 639....4766
Event Code 652 - 659....4767
Event Code 660 - 667....4768
Event Code 660 - 663....4768
Event Code 664 - 667....4768
Event Code 668 - 672....4769
Event Code 668 - 671....4769
Event Code 672....4769
Event Code 700....4770
Event Code 701....4771
Event Code 702....4772
Event Code 707....4774
Event Code 708 & 709....4775
Event Code 711 - 720, 736....4776
Event Code 711 - 720....4776
Event Code 736....4776
Event Code 737....4777
Event Code 738 - 739....4778
Event Code 738....4778
Event Code 739....4778
Event Code 740....4779
Event Code 741 - 742....4780
Event Code 741....4780
Event Code 742....4780
Event Code 743....4781
Event Code 744 - 745....4782
Event Code 744....4782
Event Code 745....4782
Event Code 746....4783
Event Code 747 - 749, 750....4784
Event Code 747 - 749....4784
Event Code 750....4784
Event Code 751....4786
Event Code 752....4787
Event Code 753....4788
Event Code 754....4789
Event Code 755....4790
Event Code 756....4791
Event Code 757 - 759....4792
Event Code 757....4792
Event Code 759....4792
Event Code 760....4794
Event Code 761....4795
Event Code 762 & 763....4796
Event Code 762....4796
Event Code 764....4797
Event Code 765....4798
Event Code 767....4799
Event Code 768....4800
Event Code 769 & 770....4801
Event Code 769....4801
Event Code 770....4801
Event Code 771 & 772....4802
Event Code 771....4802
Event Code 772....4802
Event Code 773 & 774....4803
Event Code 773....4803
Event Code 774....4803
Event Code 775....4804
Event Code 776....4805
Event Code 777....4806
Event Code 778 & 779....4807
Event Code 778....4807
Event Code 779....4807
Event Code 780....4808
Event Code 781....4809
Event Code 782....4810
Event Code 783....4811
Event Code 784....4812
Event Code 785, 790 & 799....4813
Event Code 790 & 799....4813
Event Codes 800....4814
Event Code 801....4815
Event Code 802....4816
Event Code 803....4818
Event Code 804....4819
Event Code 805....4820
Event Code 806....4822
Event Code 807....4823
Event Code 816, 821 & 822....4824
Event Code 816....4824
Event Code 821....4824
Event Code 822....4824
Event Code 823....4825
Event Code 824....4826
Event Code 825....4827
Event Code 836 - 837....4828
Event Code 836....4828
Event Code 837....4828
Event Code 838....4829
Event Code 839....4830
Event Code 840....4831
Event Code 841, 842....4832
Event Code 841....4832
Event Code 842....4832
Event Code 843....4833
Event Code 844....4834
Event Code 845, 846....4835
Event Code 845....4835
Event Code 846....4835
Event Code 847....4836
Event Coder 848....4838
Event Code 849....4840
Event Code 850 - 852....4842
Event Code 853 - 855....4843
Event Code 856 - 859....4844
Event Code 860 - 863....4845
Event Code 864 - 867....4846
Event Code 868 & 869....4847
Event Code 870 & 871....4848
Event Code 872 - 874....4849
Event Code 875 - 877....4851
Event Code 878 - 880....4853
Brake System....4855
General....4857
Function....4857
Stopping Distance....4857
Brake Adjustment....4858
Air Gap Adjustment....4858
Torque Gap Adjustment....4859
Rotor and Brake Pad Replacement....4860
Disassembly....4860
Assembly....4861
Troubleshooting....4862
Steering....4863
Steering Feedback....4865
Replacing Steering Feedback Assembly Encoder....4865
Replacing Steering Feedback Assembly Gears....4866
Steering Encoder Alignment....4867
Motor....4868
Minimum Brush Lengh....4868
Replacing the Brushes....4868
Replacing Steering Motor....4869
Replacing Steering Gearbox....4871
Lifting Mechanism....4873
Mast Types....4875
TN - Mast....4875
TF - Mast....4875
Second Stage Mast Removal....4876
Removing Second Stage Mast....4876
Removing Without Sufficient Overhead Clearance....4876
Removing With Sufficient Overhead Clearance....4880
Roller Adjustment....4880
Column Rollers....4880
Side Thrust Rollers....4880
Installing Second Stage Mast Without Sufficient Overhead Clearance....4881
Installing Second Stage Mast With Sufficient Overhead Clearance....4882
Hose Take-Up Cable....4883
Cable Removal....4883
Cable Installation....4885
Load Wheels....4886
Load Wheel Removal....4886
Tire Replacement....4886
Lathe Cutting....4887
Lift Chains....4888
Inspection....4888
Cleaning....4888
Wear....4888
Freedom of Movement of Chain Links....4889
Chain Tension....4889
Chain Anchor and Pulleys....4890
Worn Connection Plates....4890
Protruding or Turned Chain Pins....4890
Corrosion....4890
Chain Lateral Wear....4891
Uneven Chain Tension....4891
Misaligned Lift Components....4891
Lift Chain Lubrication....4892
Separating Lift Chains....4893
Tools and Equipment Required....4893
Separation....4893
Fork Inspection....4894
Inspection Intervals....4894
Fork Blade Abrasion Check....4894
Measurement....4894
Hanger Bore Measurement....4895
Overloading....4895
Fatigue....4896
Bent or Twisted Forks....4896
Hanger....4897
Cylinders....4899
TF Lift Cylinders....4901
General....4901
Pivoting The Tip-Out Assembly....4901
Primary Lift Cylinder Repair....4904
Cylinder Packing Installation....4906
Installation of Tip-Out Assembly....4906
Primary Lift Cylinder Removal....4907
Secondary Lift Cylinder Removal....4908
Primary Lift Cylinder Installation....4909
Secondary Lift Cylinder Installation....4909
Lift Cylinder Bleeding....4910
TN Lift Cylinder....4911
Pivoting The Tip-Out Assembly....4911
Lift Cylinder Repair....4913
Cylinder Packing Installation....4915
Installing the Tip-Out Assembly....4915
Lift Cylinder Removal....4916
Lift Cylinder Installation....4917
Lift Cylinder Bleeding....4918
Auxiliary Lift Cylinder....4919
Repair....4919
Rod Packing Installation....4921
Auxiliary Lift Cylinder Bleeding....4921
Fork Cylinders....4922
Cylinder Disassembly....4922
Piston Rod Disassembly....4923
Reassembly....4924
Pivot Cylinders....4926
Cylinder Removal....4926
Cylinder Disassembly....4927
Cylinder Reassembly....4928
Cylinder Installation....4929
Pivot Cylinder Bleeding....4929
Platform....4931
Inspection and Adjustment....4933
Column Roller Area....4933
Overhead Guard Area....4933
Operator Controls....4933
Lower Platform Area....4933
Lubrication....4935
Mast Shield Removal....4936
Gates....4937
Gate Switches GTSL & GTSR....4938
Adjustments....4939
Chain Anchors and Platform Height....4939
Side Thrust Roller Adjustment - Platform....4939
Traverse Hose Replacement....4941
Removal....4943
Assembly....4945
Seat....4946
Seat Pivot Bearing Assembly....4946
Seat Position Switch Adjustment....4946
Seat Coil Cord Installation....4947
Seat Up/Down Switch Adjustment....4948
Mirror....4950
Installation....4950
Adjustment....4952
Height Sensing System....4953
Height Sensor Assembly Removal and Installation....4953
Removal....4953
Height Cable Broken Switch (HCS)....4954
Replacement of components....4954
Height Sensor Assembly....4955
Cable Replacement....4956
Glossary....4959
Index....4961
Schematic Diagrams....4977
Platform....4979
Power Unit....4980
Platform Distribution Panel....4981
Power Unit Distribution Panel....4982
Lights and Fans....4983
Operator Display....4984
Platform Chain Switches....4985
Vehicle Control Module....4986
Platform Seat Area....4987
Platform Floor Area....4988
Traction Control Module....4989
Steering Control Module....4990
Contactor Panel....4991
Traction Motor, FSB1 & Brake....4992
Hydraulic Control Module....4993
Hydraulic Motor....4994
Operator Control Module....4995
Left Armrest - Platform....4996
EAC & Guidance Control Module....4997
Traction Motor, FSB1,FSB2 & Brake....4998
Accessory Control Module....4999
Power Cables....5000
Wire Harness....5001
Hydraulic Schematic....5003
Manifold Block Main Frame & Lift Cylinders....5005
Manifold Block Load Handler, with extending Forks....5006
Manifold Block Load Handler, with tilting Forks....5007
WAV-50....5009
1 PF11229-00C master service & parts....5010
Cover....5010
Blank page....5011
MA....5013
MA-2450-001....5012
MA-2350-050....5013
MA-2350-100....5014
This page....5021
IDX-2450-200....5022
ITD-2450-001....5027
M1.0....5030
M1.0-2450-001....5030
M1.0-2450-010....5032
M1.0-2450-050....5038
M1.9-2350-001....5058
M2.0....5060
This page....5059
M2.0-2350-001....5060
M2.1-2350-001....5062
M2.6-2350-001....5063
M2.9-2350-001....5064
M3.0....0
M3.0-2350-001....5066
M3.2-2350-001....5072
M4.0....5074
M4.0-2450-001....5074
M4.0-2450-020....5079
M4.0-2350-030....5083
M4.0-2450-040....5085
M4.0-2350-060....5086
M4.0-2350-080....5090
M4.0-2350-100....5094
M4.1-2350-001....5096
M4.2-2450-015....5098
M4.2-2450-210....5106
M4.3-2350-001....5114
M4.3-2450-050....5117
M4.4-2450-001....5118
M4.6-2450-007....5120
This page....5125
M4.7-2350-001....5126
M4.8-2350-100....5127
M4.8-2450-001....5142
M5.0-2350-001....5144
M7.0....0
M7.0-2350-001....5146
M7.0-2350-015....5152
M7.5-2350-001....5160
M8.0-2350-001....5168
This page....5175
M9.0-2350-004....5176
This page....5179
M10-2450-010....5180
DIA....0
DIA-2450-017....5192
DIA-2450-050....5202
01.0....0
This page....5212
01.0-2450-009....5213
01.0-2350-052....5217
01.5-2350-050....5219
02.0-2450-001....5221
03.0-2350-003....5223
03.2-2350-001....5225
04.0....0
04.1-2450-003....5227
04.4-2350-001....5229
This page....5230
04.4-2450-001....5231
04.6-2450-003....5233
04.6-2350-050....5235
04.6-2450-050....5239
04.8-2450-001....5243
04.8-2450-050....5245
04.8-2350-075....5247
04.8-2350-100....5249
This page....5250
04.8-2350-152....5251
04.8-2350-200....5253
04.8-2350-252....5255
07.0....5257
07.2-2450-003....5257
07.2-2350-025....5259
07.2-2350-052....5263
07.5-2350-001....5267
This page....5268
08.0-2350-002....5269
09.0....0
09.0-2350-006....5271
09.0-2350-050....5275
10.0....0
10.0-2350-001....5277
This page....5278
10.0-2350-022....5279
10.0-2350-100....5281
10.9-2450-007....5283
11.0....0
11.0-2450-001....5287
This page....5290
11.0-2450-050....5291
This page....5293
Inside back cover....5294
Back cover....5295
Lube and adj M1.0-2350-001....5296
Lube and adj M1.0-2350-010....5298
Settings M4.2-2350-210....5304
General Information....5304
Programmable Features & Calibration....5304
Programmer....5304
Cloning Controllers....5305
Feature Descriptions....5305
Trouble codes 118 M4.2-2350-425[1]....5312
Troubleshooting Indicators-Display....5312
Troubleshooting Aids-Handset....5312
Service Codes....5313
Code 1, 2....5314
Code 3, 5....5315
Code 6, 7....5316
Code 8, 16....5317
Code 17, 18....5318
Code 19, 20....5319
Code 21, 23....5320
Code 24, 25....5321
Code 26, 27....5322
Code 28, 29....5323
Code 30, 31....5324
Code 32, 34....5325
Code 35, 36....5326
Code 37, 38....5327
Code 39, 40....5328
Code 41, 42....5329
Code 43, 44, 45....5330
Code 49, 50....5331
Code 128, 136....5332
Code 160, 192....5333
Trouble codes Wav-50 M4.2-2350-400....5334
WAV-50- 84 DIA-2350-019....5356
WAV-50-118 CROWN_DIA-2350-100....5365
DIA-2350-100....5365
DIA-2350-101....5366
DIA-2350-102....5367
DIA-2350-103....5368
DIA-2350-104....5369
DIA-2350-105....5370
DIA-2350-106....5371
DIA-2350-107....5372
DIA-2350-108....5373
WAV50....5374
WAV50....5374
Safety instructions....5382
General maintenance....5384
Equipment Cleaning....5386
WAVE® Vehicle Procedures....5386
Control of Hazardous Energy....5387
Lockout/Tagout....5387
WAVE® Work Assist Vehicle....5387
Battery....5387
Safety rules....5387
Charging....5388
Battery removal....5389
Battery installation....5389
Battery Lockout/Tagout....5390
Hydraulic....5391
Lifting and blocking....5392
Mast....5393
Capacitance....5395
Introduction....5396
Operator instructions....5398
Service training....5398
Publications....5398
Data plate....5399
Model number example....5399
Vehicle data number example....5400
LUBRICATION & adjustment....5402
Maintenance program....5404
Lubricants and maintenance products....5405
Component Accessibility....5406
Chassis....5407
Load Deck (1)....5407
Contactor Panel (2)....5407
Rear Chassis Cover (3)....5407
Service Panel (5)....5408
MRC Controller....5408
Battery Charger....5408
Platform/Mast third Stage....5409
Steering Control Pod (2)....5410
Traction Control Pod (9)....5410
Mast Cap (10)....5410
Floorboard....5410
Gates....5410
Lubrication....5411
Torque Values....5421
Standard Screws/Bolts....5421
Grade....5421
Torque Chart - Standard Screws/Bolts....5421
Self Locking Screw/Nuts....5422
Grade....5422
Torque Chart - Self Locking Screws/Nuts....5422
HYDRAULIC SYStem....5424
Hydraulic schematic symbols....5426
Functional Description....5427
Reservoir....5427
Hydraulic Oils....5427
Manual Lowering....5428
Accumulator Operation....5428
Hydraulic Lines and Fittings....5429
Lift Relief Valve Setting....5430
Accumulator....5431
Precharging....5432
Hydraulic Troubleshooting....5433
Drive unit....5436
Drive Unit Gearbox Lubrication....5438
Gearbox Replacement....5441
Wheels....5442
Drive Wheel Replacement....5443
Caster Wheel Replacement....5444
Electrical maintenance....5446
Component Accessability....5449
Chassis (under load deck)....5449
Chassis (under platform)....5451
Steering Control Pod....5452
Traction Control Pod....5452
Platform Floor Components....5453
Switches....5454
Potentiometers....5460
POT1 Steering Potentiometer....5460
POT1 Steering Potentiometer Linkage Adjustment....5460
POT2 Traction Potentiometer....5462
Fuses....5463
Control Cables....5465
2135 mm (84 in) Lift Height....5465
Control Cable Re-tension....5466
Cable Replacement....5467
2995 mm (118 in) Lift Height....5469
Control Cable Re-tension....5470
Cable Replacement....5471
Keypad....5474
Keypad Programming Features....5475
Keypad Specifications....5476
Keypad Block Diagram....5476
Keypad Replacing Key Switch....5476
Part of Platform Wiring Diagram....5476
Wiring Color Codes....5477
Color....5477
Number....5477
System controller, CURTIS 1703....5480
Maintenance....5480
Safety....5480
Cleaning....5480
Special Tools....5481
Mini Fit Connector....5481
Curtis Handset....5481
Handset Operation....5482
Handset Menus....5484
Program Menu....5484
Faults Menu....5488
Functions Menu....5489
Information Menu....5489
Programmer Setup Menu....5489
Controller Settings....5490
Features and Calibration....5491
Handheld Programmer....5491
Cloning Controllers....5491
Feature Description....5492
Controller Troubleshooting....5500
Display Troubleshooting Indicators....5500
Handset Troubleshooting Aids....5501
Service Codes....5502
Hydraulic Interaction....5523
Static Condition....5523
Platform Raise....5525
Platform Lower....5527
Tilt Sensor....5529
Contactor....5530
Contactor ED (Emergency Disconnect) 24 V....5530
Inspection....5530
Contacts....5530
Coil....5530
Component Replacement....5531
Contact Replacement....5531
Coil Replacement....5532
Battery....5533
Battery Discharge Indicator, Lift Interrupt....5533
Battery....5534
Safety Rules....5535
Inspection....5535
Cleaning....5535
Maintenance Free Batteries....5535
Charger....5536
Charging Requirements....5536
Charging....5537
Abnormal Charge Sequence....5538
Battery Testing....5538
Troubleshooting....5539
Motors....5540
Inspection....5540
Traction Motor....5540
Removal....5540
Brush and Spring Removal....5540
Lift Pump Motor....5541
Removal....5541
Brush and Spring Removal....5541
Current Readings....5541
Service Panel....5542
Brake Maintenance....5546
Brake System....5548
Regenerative Braking....5548
Parking brake....5548
Parking Brake Wear....5549
MAST Maintenance....5550
2135 mm (84 in) Lift Height....5551
Torque Requirements....5552
Mast Disassembly....5552
Mast Maintenance....5553
Mast Assembly....5553
Mast Reshimming....5557
Top Shims and Guides....5557
Bottom Shims and Guides....5560
2995 mm (118 in) Lift Height....5561
Torque Requirements....5562
Mast Disassembly....5562
Mast Maintenance....5564
Mast Assembly....5564
Mast Reshimming....5569
Top Shims and Guides....5569
Bottom Shims and Guides....5572
Lift Chain....5573
Inspection....5573
Wear....5573
Rust and Corrosion....5574
Cracked Plates....5574
Tight Joints....5575
Protruding or Turned Pins....5575
Chain Side Wear....5575
Unequal Chain Tension....5575
Non Alignment of Lift Components....5575
Lift Chain Lubrication....5576
Lift Chain Replacement....5576
Lift Chain Removal....5576
Secondary Chain Replacement....5579
Leaf Chain Disconnect....5581
Cylinder Maintenance....5582
General....5584
Cylinder Removal....5585
Disassembly....5587
Hydraulic Seals....5588
Hydraulic Seal Installation....5588
Installation Tool....5589
Installation Procedure....5589
Cylinder Replacement....5591
Velocity Fuse Replacement....5594
Cylinder Bleeding....5595
Cylinder Summary....5595
Platform maintenance....5596
Load Tray....5598
Operation....5598
Load Tray Disassembly....5600
Load Tray Assembly....5600
Glossary....5602
Audible Indicators....5605
Battery....5605
Connections....5606
Contactors/Relays....5609
Diode Blocks....5610
Fuses....5610
Lights....5611
Miscellaneous....5612
Solenoid Valves....5615
Suppressor Blocks....5615
Switches....5616
System/Modules....5622
Electrical Diagrams....5624
Diagrams (2135 mm, 84 in)....5626
Block Diagram....5627
Schematic....5628
Platform....5629
Chassis....5630
Contactor Panel....5631
Power Cables....5632
Wire Harnesses....5633
Diagrams (2995 mm, 118 in)....5634
Block Diagram....5635
Schematic....5636
Platform....5637
Chassis....5638
Contactor Panel....5639
Power Cables....5640
Wire Harnesses....5641
WD2300S....5642
WD2300S....5643
WD2300S....5643
Safety....5653
Symbols Used in the Manual....5655
Caution....5655
General Safety Instructions....5656
Maintenance and Repair Instructions....5656
Maintenance and Repair....5656
Before Parking the Truck....5657
Before Working on the Truck....5657
Before Starting the Truck....5657
Warning and Instruction Decals on the Truck....5657
Introduction....5659
Introduction....5661
General....5661
Operator manual....5661
Service Training....5661
Ordering Spare Parts....5661
Using the Manual....5662
Lubrication & Adjustment....5663
Lifting the Truck....5665
Lifting by Crane....5665
Lifting with another Forklift Truck....5665
Jacking up the Truck....5666
Towing the Truck....5667
Caution....5667
Accessing the Components....5668
Power unit cover....5668
Control handle....5668
Control handle knuckle....5668
Mast....5669
Platform and side restraint....5669
Maintenance....5671
Recommended Lubricants and Oils....5671
Lubricants....5671
Cold Store Trucks....5671
Taking the truck out of service....5671
Returning the Truck to Service....5671
Inspection and Maintenance Schedule....5673
Testing the Operation of the Safety Reverse Switch....5677
Inspection and Maintenance Schedule....5678
Lubrication Points....5683
Drive Wheel and Castor Wheels....5684
Setting the contact pressure....5684
Torques....5686
Hydraulics....5689
Hydraulic Symbols....5691
Hydraulic Unit Removal....5695
Hydraulic System....5696
Function....5696
Lifting (Main Lift)....5696
Lowering (Main Lift)....5696
Lifting (Initial Lift)....5696
Lowering (Initial Lift)....5696
Hydraulic Reservoir Capacity....5700
Changing the Hydraulic oil and Hydraulic Filter....5700
Motor & Pump Assembly....5702
Hydraulic lines and fittings....5702
General Rules for Hydraulic Lines and Connections....5702
Bleeding the Hydraulic System....5703
Drift Test....5703
Disassembly....5703
Motor....5704
Pump....5704
Relief Valve....5707
Replacing the relief valve....5707
Relief valve setting....5707
Relief valve test and setting....5708
Testing and setting the load-sensing pressure switches....5709
Setting the pressure switch points....5710
Pressure switch PS1....5710
Pressure switch PS2....5710
Pressure switch PS3....5710
Power Unit....5711
Gear Unit....5713
Preparatory Measures....5713
Tools required:....5713
Disassembly....5713
Servicing....5714
General....5714
Gear Unit Disassembly / Assembly....5716
Disassembly....5716
Assembly....5717
Preparing the gear unit....5717
Assembling the flange shaft....5717
Pinion Shaft Aassembly....5718
Adjusting the Bevel Wheel Set....5718
Checking the Flank Tooth Bearing....5719
Final Assembly....5719
Re-Assembly....5720
Traction motor....5720
Electrical System....5721
Wire Colour Code....5723
Abbreviations....5724
Sundry Abbreviations....5725
Electrical Wiring Diagrams....5726
Electrical Components....5728
Traction Pod (POT, FS, RS)....5728
Fast / Slow Travel Switch (HSS)....5728
Safety Reverse Switch (SAS)....5728
Brake Switch (BRS)....5728
Horn Switch (HNS1 & 2)....5729
Key Switch (KYS)....5729
Emergency Disconnect (BD)....5729
Fuses (FU)....5729
Thermo Switch (THS, optional)....5729
Diode D4....5729
Diode Block (DB)....5729
Platform Logic (PLM)....5729
Limit Switch (LMS1)....5730
Limit Switch (LMS 2, only for masts > 1700mm)....5730
Limit Switch (LMS3, only for masts > 1700mm)....5730
Limit Switch LMS4....5730
Pressure Switch (PS1)....5730
Pressure Switch (PS2)....5730
Pressure Switch (PS3)....5730
Initial lift Switch....5730
Hydraulic Control Module (HCM)....5731
Raise / Lower Switches (RAS, LOS)....5731
Control Handle Main PCB (Main PCB)....5731
Hydraulic PCB (Hydr. PCB)....5731
Speed Transmitter PCB (R/T PCB)....5731
Heating Option (F/C)....5731
Battery....5733
General....5733
Replacing the Battery....5733
Battery Discharge Indicator (BDI)....5734
Operation....5734
General....5735
Battery Discharge Indicator Setting (BDI)....5735
Calibration for Wet Batteries....5736
Troubleshooting....5737
Contactors....5738
Inspection....5738
Contacts....5738
Coils....5738
Springs....5738
Servicing....5739
Dismantling....5739
Assembly....5739
SEM1 Traction Controller....5740
General....5740
Precautionary Measures....5740
Operating Characteristics....5740
Speed control....5740
Reduced Travel Speed Zones....5741
Downhill Speed Control....5741
Regenerative Braking....5741
Anti Roll Down Function....5741
Hourmeter....5741
Self-Diagnostic System....5741
Monitored Circuits....5742
Safety Mechanisms....5742
Incorrect polarity....5742
Wiring Errors....5742
Temperature protection....5742
Start sequence....5742
Protection rating....5742
Maintenance....5743
Replacing the SEM1 Traction Controller....5744
Parameter Setting after Replacing the Traction Controller....5745
Preparatory Measures....5745
Adjustment....5745
Status LED....5748
Travel Speed Test....5749
Programmer....5750
General....5750
SEM1 Traction Controller Operating Menu....5752
General....5752
Menu Functions....5752
PARAMETER CHANGE....5752
TEST....5752
ALARMS....5752
PROGRAM VACC....5752
CONFIG....5752
Menu Structure for Folding Platform....5753
Parameter Setting, Folding Platform....5754
TESTER Menu....5757
Max. speed in relation to the reductionlevel....5758
ALARMS Menu....5759
Traction Pod....5762
Calibrating the Potentiometer, PROGRAM VACC Menu....5762
Preparatory Measures....5762
Calibration....5762
CONFIG Menu....5764
SET MODEL....5764
SET OPTIONS....5764
ADJUSTMENTS....5764
Traction Controller Safety Test....5765
WD2300S Platform Logic Box....5766
Platform Logic Controller, Part No. 816050....5766
Checking the Platform Logic....5770
Hydraulic Control Module (HCM), Part No. 816177....5771
Operation....5771
Calibrating the HCM....5773
Electric Motors....5774
General Maintenance Instructions....5774
Preparatory Measures....5774
Important Maintenance Instructions....5774
Traction Motor Maintenance....5775
Access to brushes....5775
Maintenance....5775
Armature....5776
Bearings....5776
Pump Motor Maintenance....5777
Access to brushes....5777
Maintenance....5777
Armature....5777
Brake....5779
Brake....5781
Dismantling....5782
Test and Inspection....5782
Assembly....5783
Caution....5783
Air Gap Setting....5784
Braking Torque Setting....5784
Brake Test....5785
Steering....5787
Control Handle Return Springs....5789
Caution....5789
Adjustment....5789
Disassembly....5789
Installation....5790
Control Handle Grip....5791
Main Components....5791
Control Handle Grip Components....5792
Caution....5792
Hand Grip Shells....5792
Upper and lower shell removal....5792
Upper and lower shell assembly....5794
Switch Unit....5794
Disassembly....5794
Switch unit assembly....5795
Disassembly....5796
Installation....5796
Hydraulic PC Board....5796
Disassembly....5796
Installation....5797
Main board removal/installation....5797
Potentiometer....5798
Disassembly....5798
Installation....5799
Safety Reverse Switch....5799
Disassembly....5799
Installation....5800
Horn Switch....5801
Disassembly....5801
Installation....5801
Hand Grip....5801
Disassembly....5801
Installation....5802
Initial Lift Switch....5802
Disassembly....5803
Installation....5803
Mast/Lift Mechanism....5805
Lift Linkage....5807
Adjusting the Fork Height....5807
Fork Adjustment....5808
Adjusting the fork height....5808
Mast....5810
General....5810
Torque Requirements....5810
Lifting Gear Minimum Capacity....5810
Mast Removal....5810
Caution....5810
Installation....5812
Fork Carriage Removal....5813
Fork Carriage Installation....5813
Fork Carriage Adjustment....5814
Mast Maintenance....5815
Lubricating Roller Tracks....5815
Mast Shims....5816
Lowering Plumb Test....5818
Preparatory Measures....5818
Carrying Out The Vertical Plumb Test....5818
Lift Limit Cutout / Initial Lift....5819
Lift Limit Cutout Setting....5819
LMS 2-4 Limit Switch Adjustment....5820
Lift Limit Cutout Setting....5820
Connecting the Lift Limit Switches....5822
Lift Chains....5823
General....5823
Inspection....5823
Cleaning....5824
Wear....5824
Freedom of Movement of Chain Links....5825
Chain Tension....5825
Chain Anchor and Pulleys....5825
Worn Connection Plates....5826
Protruding or Turned Chain Pins....5826
Corrosion....5827
Chain Lateral Wear....5827
Uneven Chain Tension....5827
Misaligned Lift Components....5827
Lift Chain Lubrication....5828
Separating Lift Chains....5829
Separation....5829
Fork Tines....5830
General....5830
Terms....5830
Fork Identification....5830
Repairs....5831
Fork Inspection....5831
Verticality Test....5832
Fork Blade Warping....5833
Measuring the Fork Tip Width....5833
Fork Tine Height Difference....5833
Fork Stop....5833
Fork Blade Wear....5834
Cylinders....5835
Cylinders....5837
General....5837
Safety when working on hydraulic systems....5837
General Instructions for Repairing Hydraulic Components....5837
General....5837
Plunger Cylinders....5838
Piston Cylinders....5840
Single-Acting Cylinder....5841
Double-Acting Cylinder....5841
Rod Seal Assembly....5842
General....5842
Large Rod Seal Assembly....5843
Small Seal Rod Assembly....5844
Rod Seal Assembly, Sealing Lip First....5845
Initial Lift Cylinder....5847
Operation....5847
Disassembly....5848
Inspection....5849
Replacing the rod seal....5849
Free Lift Cylinder....5850
Seal Replacement....5850
Installing Carriage Cylinder....5852
Cylinder Bleeding and Flushing....5853
Free lift cylinder bleeding....5853
Flushing - Mast Lift Cylinders and Free Lift Cylinders....5853
Drift Test....5853
Platform....5855
Mechanical Adjustment....5857
Platform Switch (PLS) Adjustment....5859
Platform Cushioning....5860
Layering the disk springs....5860
Side Restraint, Mechanical Adjustment....5861
Electrical wiring diagrams....5863
Standard Diagrams....5866
Overview....5866
Traffic Control Logic Circle....5868
Traffic Control Load Circle....5869
Hydraulic Traffic Modul and Diodes Block....5870
Power Unit Control Circle....5871
Control Handle Control Circle....5872
Platform & Mast Control Circle....5873
Platformmodul....5874
Option Wiring Diagrams....5876
Overview....5876
Traffic Control Logic Circle....5878
Traffic Control Load Circle....5879
Hydraulic Traffic Modul and Diodes Block....5880
Power Unit Control Circle....5881
Control Handle Traffic Circle....5882
Platform & Mast Traffic circle....5883
Platformmodul....5884
Power Cables....5886
Legend....5887
Main Wire Harness....5888
Folding platform, all versions....5888
Control Handle Wire Harness....5889
Horn Switch Wire Harness....5890
HydrauliC DIAGRAMS....5891
Hydraulic Diagrams....5894
WE_WS....5897
MS-WE_WS2000....5898
WE/WS ....5898
ELECTRICAL DIAGRAMS....6105
Schematic Wiring Diagram....6105
Distribution Panel....6106
Handle and Travel Timer....6107
Traction Controller....6108
Brake and Charger Cicuit....6109
WE/WS Option Softlift Schematic....6111
WE/WS Option Softlift....6112
Handle and Travel Timer....6113
Traction Controller....6114
Brake and Charger Cicuit....6115
Proportional Electronic....6116
INDEX....5899
IDX - 4220 - 002....5900
IDX - 4220 - 003....5901
IDX - 4220 - 004....5902
INTRODUCTION....5917
General....5917
Using the manual....5917
Maintenance....5917
Spare parts catalog....5918
page numbers....5918
Operating instruction....5919
Service training....5919
Replacement parts ordering....5919
GENERAL MAINTENANCE INSTRUCTION....5921
SAFETY INSTRUCTIONS....5921
MAINTENANCE....5925
COMPONENT ACCESS....5925
RAISING THE VEHICLE....5926
Support Points....5927
INSPECTION AND MAINTENANCE PLAN....5929
Service scope....5929
DAILY OR AFTER 8 HOURS OF OPERATION....5930
Illustration....5931
MONTHLY OR EVERY 100 HOURS OF OPERATION....5932
Illustration....5933
QUARTERLY OR EVERY 250 HOURS OF OPERATION....5934
EVERY SIX MONTHS OR EVERY 500 HOURS OF OPERATION....5934
Illustration....5935
YEARLY OR EVERY 1000 HOURS OF OPERATION....5936
JÄHRLICH ODER ALLE 1000 BETRIEBSSTUNDEN....5936
Illustration....5937
LUBRICATION....5939
General....5939
Cold store trucks....5939
Operator involvement....5939
Daily Maintenance Check....5939
LUBRICANTS AND OIL RECOMMENDATIONS TABLE....5941
TORQUE VALUES....5943
HYDRAULIC SCHEMATIC SYMBOLS....5945
HYDRAULIC....5957
General....5957
HYDRAULIC OIL TANK....5958
Cover on hydraulic oil tank....5958
Disassembly....5958
Assembly....5959
Maintenance....5960
Valve block....5961
Disassembly....5961
Repair....5961
Assembly....5961
Hydraulic oil pump....5962
Disassembly....5962
Assembly....5962
Repair....5962
HYDRAULIC SYSTEM SOFTLIFT....5963
General:....5963
Description:....5963
Lowering speed:....5964
Bleed procedure:....5964
Troubleshooting:....5964
Vent hydraulic system on mast TF and TT....5965
TL MAST....5965
DRIVE UNIT....5967
Drive wheel....5967
Disassembly....5967
Assembly....5967
DRIVE UNIT....5968
General....5968
Disassembly....5968
Assembly....5969
Gearbox....5969
Disassembly....5969
Assembly....5970
Repair....5971
Assembly....5972
Maintenance, oil change....5973
Turntable bearing....5974
Disassembly....5974
Assembly....5974
PIVOTING CARRIAGE....5975
General....5975
Disassembly....5975
Assembly....5976
Setting the pivoting carriage, type WE truck....5976
Setting the pivoting carriage, type WS truck....5976
WHEELS AND TYRES....5977
General....5977
Load wheel, single axle....5977
Disassembly....5977
Assembly....5977
Load wheel, tandem axle....5978
Disassembly....5978
Assembly....5978
Support wheel....5978
Disassembly....5978
Assembly....5979
Support wheel mounting....5979
Disassembly....5979
Assembly....5979
ELECTRIC....5981
BASIC ELECTRICS....5981
WIRING COLOUR CODE....5981
COLOUR CODING IN ACCORDANCE WITH DIN 47100....5982
Index of AbbreviationsSwitch Symbols....5983
Other Abbreviations....5984
Typical Electrical Symbols....5985
Transistor control....5986
ELECTRICAL COMPONENTS....5989
SAFETY INSTRUCTIONS....5989
SWITCHES....5989
General....5989
Key switch (KYS)....5989
Brake switch (BRS)....5989
Safety reverse switch (SAS)....5989
Direction control (POT, FS, RS)....5989
Lift/Lower switches (RAS, LOS)....5990
Brake override switch (ORS)....5990
Horn (HNS)....5990
Speed limiter switch (LMS)....5990
Battery connector/Emergency Battery Disconnect....5990
Fuses (FU)....5990
Electric Parts Layout....5991
CONTROLLER (1207-1115)....5993
General....5993
Function....5994
Emergency reverse....5994
Acceleration/deceleration rate....5994
Brake....5994
Throttle....5994
Throttle response....5994
Fault recording....5995
Fault detection....5995
Plug braking....5996
Creep speed at first throttle....5996
Low speed....5996
MOSFET....5997
Pulse with modulation....5997
Ramp start (anti roll-back)....5997
Key switch....5997
Quick start....5997
Watchdog (external, internal)....5998
Current limiting....5998
Overvoltage cutoff....5998
Overtemperatur....5998
Undervoltage cutback....5998
Pilot wire pins (Model 1207)....5999
ADJUSTMENT PANEL....6000
Manually adjustable potentiometer....6000
Programmer connector....6000
Status LED....6000
LED Diagnostics....6000
LED CODES....6001
MAINTENANCE....6003
SAFETY....6003
Cleaning of the controller....6003
Removal/Installation....6004
CONTROLER CHECK....6006
PROGRAMMER....6009
General....6009
Connections....6009
Keypad definition....6010
Display....6011
OPERATING MODES....6014
PROGRAM MODE....6014
TESTMODE....6015
DIAGNOSTIC MODE....6016
SPECIAL DIAGNOSTIC MODE....6016
SPECIAL PROGRAM MODE....6016
Programmer Self Test....6018
VALUES AND FAULT CODES....6019
WE 1.25t/WS 1.35t....6019
WE 1.6t/WS 1.8t....6021
PROGRAM MENU....6023
TEST MENU....6024
Diagnostic and Special Diagnostic Menu....6025
Trouble shooting chart....6027
BDI / TT....6031
Disassembly....6031
Repairs....6031
Assembly....6031
KEY SWITCH KYS....6033
Disassembly....6033
Repairs....6033
Assembly....6033
Reverse safety switch SAS....6034
Disassembly....6034
Assembly....6034
Drive switch FS/RS....6034
Disassembly....6034
Assembly....6035
Setting drive switch....6036
Checking settings....6036
Raise switch (RAS)/lower 1 (LOS1)/lower 2 (LOS2)....6037
Disassembly....6037
Assembly....6037
Horn switch (HMS)....6038
Disassembly....6038
Assembly....6038
Speed limit switch (LMS)....6038
Disassembly....6038
Assembly....6039
Brake switch (BRS)....6039
Disassembly....6039
Assembly....6040
Override switch (ORS)....6041
Disassembly....6041
Assembly....6041
Emergency Off Switch (EDS)....6042
Disassembly....6042
Assembly....6042
Distributor Board....6043
Disassembly....6043
Assembly....6043
MOTORS....6045
General....6045
PUMP MOTOR....6046
Disassembly....6046
Assembly....6046
Maintenance WE 1.25/WS1.35....6047
Repair....6047
Assembly....6049
Maintenance WE 1.6/WS1.8....6050
Repair....6051
DRIVE MOTOR....6052
Disassembly....6052
Repair....6053
Assembly....6055
Maintenance....6055
Electrics panel....6057
General....6057
Disassembly....6057
Assembly....6057
Contactor Drive Direction....6058
Checking contacts....6058
Checking coils....6058
Disassembly....6058
Repairs....6059
Assembly....6059
Unbenannt....6059
Pump contactor....6060
Disassembly....6060
Repairs....6060
Assembly....6061
Assembly....6061
BATTERY....6063
Disassembly with lifting device....6063
Assembly....6063
Removal with battery roller option:....6063
MAINTENANCE....6064
Checking the electrolyte level....6064
Charging the battery....6065
Using the battery at high temperature....6066
Daily maintenance....6066
Weekly maintenance....6066
Monthly maintenance....6066
Cleaning....6067
Storage....6067
Spilled or leaking electrolyte:....6067
Battery connections....6067
Disassembly....6067
Repair....6068
Assembly....6068
TEST PROCEDURES....6069
PMT - TEST CONNECTING DIAGRAM....6070
BRAKE....6071
Drive wheel Brakes....6071
Removal....6071
Installation....6072
Setting up Air Gap....6073
Setting up brake torque....6073
Carrying out Brake Test....6073
STEERING....6075
General....6075
CONTROL HANDLE....6076
Removal....6076
Attention....6076
Installation....6077
Cross joint steering....6078
Disassembly....6078
Assembly....6078
Chain tensioning device, steering....6079
Disassembly....6079
Assembly....6079
Steering chain....6080
Disassembly....6080
Assembly....6081
LIFTING GEAR....6083
General....6083
Single lifting gear (Simplex) TL....6083
Double lifting gear (Duplex) TF....6083
Triple lifting gear (Triplex) TT....6084
Disassembly....6084
Assembly....6085
Fork carriage....6085
Disassembly....6085
Assembly....6085
Setting the fork carrier play....6086
Mast maintenance....6086
WARNING....6086
Greasing roller tracks....6086
Disassembling rollers....6087
Assembly....6087
LIFT CHAIN INSPECTION....6089
Maintenance....6090
Detailed Explanation....6091
Cracked or Missing Link plates....6091
Pitting and Corrosion....6091
Protruding or Turned Pins....6092
Free Movement and Edge Wear....6092
Chain Length Measurement....6093
Chain Tension....6094
Chain Anchors and Pulleys....6094
FORK INSPECTION....6095
Fork Identification....6095
Repairs....6096
Visual Inspection for Cracks....6096
Straightness Inspection....6097
Fork Blade Bending....6097
Inspection of Fork Tip Thickness....6097
Fork Blade Height Difference....6098
Fork Locking....6098
Wear....6098
HYDRAULIC CYLINDER....6101
General....6101
Simplex mast cylinder....6101
Disassembly....6101
Lifting cylinder....6102
Disassembly....6102
PANELS, COVERS....6103
General....6103
Protective cover....6103
Disassembly....6103
Assembly....6103
Battery cover....6103
Disassembly....6103
Assembly....6103
Nuckle cover....6104
Disassembly....6104
Assembly....6104
Nuckle cover adjustment....6104
HYDRAULIC SCHEMATICS....6117
Simplex....6117
Duplex....6118
Triplex....6118
MAIN HARNESS....6121
KBL-4220-002....6122
KBL-4220-003....6123
Tooling / Plugs....6125
WZ-4220-002....6126
WE_WS2300 Service....6127
WE/WS2300....6127
TABLE OF CONTENT....6129
Table of Content 1....6129
Table of Content 2....6130
Table of Content 3....6131
Table of Content 4....6132
GENERAL MAINTENANCE INSTRUCTION....6141
SAFETY INSTRUCTIONS 1....6141
SAFETY INSTRUCTIONS 2....6142
SAFETY INSTRUCTIONS 3....6143
INTRODUCTION....6145
General....6145
Using the manual....6145
Maintenance....6145
Spare parts catalog....6146
Operating instruction....6147
Service training....6147
Replacement parts ordering....6147
MAINTENANCE....6149
COMPONENT ACCESS....6149
Access to the components....6149
ILLUSTRATION / BILD / ILLUSTRATION M0400....6149
RAISING THE VEHICLE....6150
WARNING!....6150
ILLUSTRATION / BILD / ILLUSTRATION M1247....6150
Support Points ILLUSTRATION M0401, ILLUSTRATION M0402....6151
INSPECTION AND MAINTENANCE PLAN....6153
Service scope....6153
DAILY OR AFTER 8 HOURS OF OPERATION....6154
ILLUSTRATION / BILD / ILLUSTRATION M0403....6155
MONTHLY OR EVERY 100 HOURS OF OPERATION....6156
ILLUSTRATION / BILD / ILLUSTRATION M0404....6157
QUARTERLY OR EVERY 250 HOURS OF OPERATION....6158
EVERY SIX MONTHS OR EVERY 500 HOURS OF OPERATION....6158
ILLUSTRATION / BILD / ILLUSTRATION M0405....6159
YEARLY OR EVERY 1000 HOURS OF OPERATION....6160
ILLUSTRATION / BILD / ILLUSTRATION M0406....6161
LUBRICATION....6163
General....6163
Lubricants....6163
Cold store trucks....6163
Operator involvement....6163
Daily Maintenance Check....6163
LUBRICANTS AND OIL RECOMMENDATIONS TABLE 1....6165
LUBRICANTS AND OIL RECOMMENDATIONS TABLE 2....6166
HYDRAULIC SCHEMATIC SYMBOLS....6167
HYDRAULIC SCHEMATIC SYMBOLS 1....6167
HYDRAULIC SCHEMATIC SYMBOLS 2....6168
HYDRAULIC SCHEMATIC SYMBOLS 3....6169
HYDRAULIC SCHEMATIC SYMBOLS 4....6170
HYDRAULIC....6179
General....6179
HYDRAULIC OIL TANK....6180
Cover on hydraulic oil tank....6180
Disassembly....6180
ILLUSTRATION / BILD / ILLUSTRATION M0410....6181
Assembly....6181
Assembly....6182
Maintenance....6182
Valve block....6183
Disassembly....6183
ILLUSTRATION / BILD / ILLUSTRATION M0412....6183
Repair....6183
Assembly....6183
Hydraulic oil pump....6184
Disassembly....6184
ILLUSTRATION / BILD / ILLUSTRATION M0413....6184
Assembly....6184
Repair....6184
HYDRAULIC SYSTEM SOFTLIFT....6185
General:....6185
Description:....6185
ILLUSTRATION / BILD / ILLUSTRATION M0439....6185
Hydraulic System, softlift....6186
Lowering speed:....6186
Bleed procedure:....6186
Troubleshooting:....6186
Vent hydraulic system on mast TF and TT Mast....6187
ILLUSTRATION / BILD / ILLUSTRATION M0411....6187
TL MAST....6187
DRIVE UNIT....6189
Drive wheel....6189
Disassembly....6189
ILLUSTRATION / BILD / ILLUSTRATION M0419....6189
Assembly....6189
DRIVE UNIT....6190
General....6190
Disassembly....6190
ILLUSTRATION / BILD / ILLUSTRATION M0414....6190
Assembly....6191
Gearbox....6191
Disassembly....6191
ILLUSTRATION / BILD / ILLUSTRATION M1154....6191
Assembly....6192
ILLUSTRATION / BILD / ILLUSTRATION M0415....6192
Repair....6193
Assembly....6194
Maintenance, oil change....6195
Turntable bearing....6196
Disassembly....6196
Assembly....6196
ILLUSTRATION / BILD / ILLUSTRATION M1155....6196
PIVOTING CARRIAGE....6197
General....6197
Disassembly....6197
ILLUSTRATION / BILD / ILLUSTRATION M0416....6197
Assembly....6198
Setting the pivoting carriage, type WE vehicle....6198
Setting the pivoting carriage, type WS vehicle....6198
WHEELS AND TYRES....6199
General....6199
Load wheel, single axle....6199
Disassembly....6199
ILLUSTRATION / BILD / ILLUSTRATION M0417....6199
Assembly....6199
Load wheel, tandem axle....6200
Disassembly....6200
ILLUSTRATION / BILD / ILLUSTRATION M0418....6200
Assembly....6200
Support wheel....6200
Disassembly....6200
Assembly....6201
Support wheel mounting,....6201
Disassembly....6201
Assembly....6201
ILLUSTRATION / BILD / ILLUSTRATION M0468....6201
BASIC ELECTRICS....6203
WIRING COLOUR CODE....6203
ABBREVIATION, COLOUR, NUMBER, FUNCTION....6203
COLOUR CODING IN ACCORDANCE WITH DIN 47100....6204
Index of Abbreviations Switch symbols *....6205
Other Abbreviations * ....6206
TYPICAL ELETRICAL SYMBOLS....6207
Transistor control with pulse width modulation....6208
ILLUSTRATION / BILD / ILLUSTRATION M0421....6208
ILLUSTRATION / BILD / ILLUSTRATION M0422....6209
ELECTRICAL COMPONENTS....6211
SAFETY INSTRUCTIONS....6211
SWITCHES....6211
General....6211
Key switch (KYS)....6211
Brake switch (BRS)....6211
Safety reverse switch (SAS)....6211
Direction control (POT, FS, RS)....6211
Lift/Lower switches (RAS, LOS)....6212
Brake override switch (ORS)....6212
Horn (HNS)....6212
Speed limiter switch (LMS)....6212
Battery connector/Emergency Battery disconnect....6212
Fuses (FU)....6212
Fast/Slow Switch (HSS)....6212
ILLUSTRATION / BILD / ILLUSTRATION 813754_2a....6213
ILLUSTRATION / BILD / ILLUSTRATION 813761_2a....6214
CONTROLLER (1207-1115)....6215
General....6215
The most important characteristics are:....6215
ILLUSTRATION / BILD / ILLUSTRATION M0024....6215
EXPLANATION OF FUNCTION....6216
Emergency reverse Only by walky trucks....6216
Acceleration/deceleration rate....6216
Brake....6216
Throttle....6216
Throttle response....6216
Fault recording....6217
Fault detection....6217
The automatic fault detection system includes:....6217
Arcless contactor switching:....6218
Plug braking....6218
Creep speed at first throttle....6218
Low speed....6218
MOSFET....6219
Pulse with modulation (PWM)....6219
Ramp start (anti roll-back)....6219
Key switch....6219
Quick start....6219
Watchdog (external, internal)....6219
Current limiting....6220
Overvoltage cutoff....6220
Overtemperatur....6220
Undervoltage cutback....6220
ILLUSTRATION / BILD / ILLUSTRATION M0025....6221
ADJUSTMENT PANEL (1207-1115)....6222
ILLUSTRATION / BILD / ILLUSTRATION M0026....6222
Manually adjustable potentiometer....6222
Programmer connector....6222
Status LED....6222
LED Diagnostics....6222
LED CODES....6223
MAINTENANCE....6225
SAFETY....6225
Cleaning of the controller....6225
REMOVAL/INSTALLATION OFTRACTION CONTROLLER....6226
SAFETY INSTRUCTIONS....6226
Removal....6226
Installation of controller....6227
CONTROLER CHECK....6228
Attention....6228
No reaction....6228
Problem....6228
Problem 2....6229
PROGRAMMER....6231
General....6231
ILLUSTRATION / BILD / ILLUSTRATION M0031....6231
Connections....6231
Keypad definition....6232
ILLUSTRATION / BILD / ILLUSTRATION M0045....6232
Display....6233
ILLUSTRATION / BILD / ILLUSTRATION M0060....6233
SCROLL DISPLAY ARROWS....6233
ILLUSTRATION / BILD / ILLUSTRATION M0032....6234
CHANGE VALUE ARROWS....6234
MORE INFO KEY....6235
OPERATING MODES....6236
PROGRAM MODE....6236
ILLUSTRATION / BILD / ILLUSTRATION M0061....6236
The MORE INFO KEY....6236
ILLUSTRATION / BILD / ILLUSTRATION M0033....6237
TEST MODE....6237
DIAGNOSTIC MODE....6238
SPECIAL DIAGNOSTIC MODE....6238
SPECIAL PROGRAM MODE....6238
For instance:....6239
Controller cloning....6239
NOTE:....6239
Peace-of-Mind Programming....6239
Programmer Self Test....6240
ILLUSTRATION / BILD / ILLUSTRATION M0046....6240
Programmer (1311)....6241
ILLUSTRATION / BILD / ILLUSTRATION 10485-1....6241
OVERVIEW....6242
ILLUSTRATION / BILD / ILLUSTRATION 10466....6242
Menu Navigation Key....6242
Bookmark Keys....6242
Display Screen....6242
Data INC/DEC Key....6242
HANDSET OPERATION....6243
ILLUSTRATION / BILD / ILLUSTRATION 10468....6243
ILLUSTRATION / BILD / ILLUSTRATION 10532....6244
ILLUSTRATION / BILD / ILLUSTRATION 10533....6244
HANDSET MENUS....6245
Program Menu....6245
Monitor Menu....6245
Faults Menu....6246
SYSTEM FAULTS....6246
Functions Menu....6246
Information Menu....6246
Programmer Setup Menu....6247
VALUES AND FAULT....6249
WE 1.25t/WE-S 1.2t/WS 1.35t....6249
WE 1.6t/WE-S 1.4t/WS 1.8t/WS-S 1.4t....6250
PROGRAM MENU Table 1 tab0001.doc....6251
TEST MENU Table 2 b0002.doc....6252
Diagnostic and Special Diagnostic Menu Table 3 b0003.doc....6253
SPECIAL PROGRAM MENU Table 4 b0004.doc....6254
Trouble shooting chart tab0011.doc....6255
Fault recovery (including recovery from disable)....6258
BATTERY LEVEL INDICATOR / OPERATING HOURS COUNTER BDI/TT....6259
Disassembly....6259
Repairs....6259
Assembly....6259
ILLUSTRATION / BILD / ILLUSTRATION M1246....6259
KEY SWITCH KYS....6261
Disassembly....6261
Repairs....6261
Assembly....6261
ILLUSTRATION / BILD / ILLUSTRATION M1156....6261
Speed limit switch....6262
Disassembly....6262
Assembly....6262
Brake switch (BRS)....6263
Disassembly....6263
ILLUSTRATION / BILD / ILLUSTRATION M1160....6263
Assembly....6263
ILLUSTRATION / BILD / ILLUSTRATION M1161....6263
Override switch (ORS)....6265
Disassembly....6265
Assembly....6265
Emergency Off switch (EDS)....6266
Disassembly....6266
Repair....6266
Assembly....6266
ILLUSTRATION / BILD / ILLUSTRATION M1162....6266
Distributor board....6267
Disassembly....6267
Repair....6267
Assembly....6267
ILLUSTRATION / BILD / ILLUSTRATION M1163....6267
MOTOR....6269
General....6269
PUMP MOTOR....6270
Disassembly....6270
ILLUSTRATION / BILD / ILLUSTRATION M0428....6270
Assembly....6270
Maintenance WE 1.25/WS1.35....6271
ILLUSTRATION / BILD / ILLUSTRATION M0429....6271
Repair....6271
Assembly....6273
ILLUSTRATION / BILD / ILLUSTRATION M0430....6273
Maintenance WE 1.6/WS1.8....6274
ILLUSTRATION / BILD / ILLUSTRATION M0616....6274
Repair....6275
DRIVE MOTOR....6276
Disassembly....6276
ILLUSTRATION / BILD / ILLUSTRATION M1154....6276
Repair....6277
ILLUSTRATION / BILD / ILLUSTRATION M0431....6278
Assembly....6279
Maintenance....6279
Electrics panel....6281
General....6281
Disassembly....6281
Assembly....6281
ILLUSTRATION M1163....6281
Direction of contactor....6282
Checking safety getting contacts....6282
Checking coils....6282
Disassembly....6282
ILLUSTRATION / BILD / ILLUSTRATION M0423....6283
Repairs....6283
Assembly....6283
Assembly....6283
Pump contactor....6284
Disassembly....6284
Repairs....6284
ILLUSTRATION / BILD / ILLUSTRATION M0424....6284
Assembly....6285
BATTERY....6287
WARNING....6287
Disassembly with lifting device....6287
Assembly....6287
BATTERY Removal with battery roller option....6287
INSTRUCTIONS ON BATTERY MAINTENANCE....6288
Checking the electrolyte level....6288
NOTE....6288
Charging the battery....6289
Trickle charging....6289
Using the battery at high temperature....6290
Daily maintenance....6290
Weekly maintenance....6290
Monthly maintenance....6290
Cleaning....6291
Storage....6291
Spilled or leaking electrolyte:....6291
Battery connections....6291
Disassembly....6291
Repair....6292
WARNING....6292
ILLUSTRATION / BILD / ILLUSTRATION M0427....6292
Assembly....6292
TEST PROCEDURES....6293
PULSE MONITOR TRIP - TEST (PMT)....6293
Equipment....6293
Test procedure....6293
ILLUSTRATION / BILD / ILLUSTRATION M0461....6293
PMT - TEST CONNECTING DIAGRAM ILLUSTRATION M0460....6294
BRAKE....6295
General....6295
Drive wheel Brakes....6295
Removal....6295
ILLUSTRATION / BILD / ILLUSTRATION M0432....6296
Note:....6296
Installation....6296
Setting up Air Gap....6297
ILLUSTRATION / BILD / ILLUSTRATION 0036....6297
Setting up brake torque....6297
Carrying out Brake Test....6297
STEERING....6299
General....6299
REMOVAL OF CONTROL HANDLE....6300
Removal....6300
Attention Pre loaded springs....6300
see Fig.M0465....6300
see Fig.M0466....6301
Installation....6301
Cross joint steering....6302
Disassembly....6302
ILLUSTRATION / BILD / ILLUSTRATION M0433....6302
Assembly....6302
Chain tensioning device, steering....6303
Disassembly....6303
ILLUSTRATION / BILD / ILLUSTRATION M0434....6303
Assembly....6303
Steering chain....6304
Disassembly....6304
ILLUSTRATION / BILD / ILLUSTRATION M0435....6304
Assembly....6305
Tiller Handle....6307
Main Components....6307
MS518....6307
Tiller Handle Component....6309
Removal / Installation....6309
MS514....6310
MS502....6310
MS501....6310
MS517....6310
MS503....6310
Tiller Handle Shells....6311
Removing the Upper and Lower Shells....6311
Fitting the Upper and Lower Shells....6311
MS513....6312
MS514....6312
Switch Unit....6313
Removal....6313
Switch Unit Installation....6313
MS511....6314
MS504....6314
"Fast/Slow" Toggle Switch....6315
Removal....6315
Installation....6315
MS511....6316
Hydraulic Board....6317
Removal....6317
Installation....6317
MS508....6318
MS509....6318
Potentiometer....6318
Removal....6318
Installation....6319
MS508....6320
Safety Reverse Switch....6320
Removal....6320
Installation....6321
MS502....6322
MS503....6322
Horn Switch....6323
Removal....6323
Installation....6323
MS501....6324
MS502....6324
Handle....6325
Removal....6325
Installation....6325
M0467....6326
Auxiliary Switch....6327
Removal....6327
Assembly....6327
LIFTING GEAR....6329
General....6329
Single lifting gear (Simplex) TL....6329
Double lifting gear (Duplex) TF....6329
Triple lifting gear (Triplex) TT....6330
Lifting gear....6330
Disassembly....6330
Assembly....6331
Fork carriage....6331
Disassembly....6331
Assembly....6331
Setting the fork carrier play....6332
If there is too much play:....6332
Mast maintenance....6332
WARNING....6332
Greasing roller tracks....6332
Disassembling rollers....6333
Assembly....6333
LIFT CHAIN INSPECTION....6335
General....6335
ILLUSTRATION / BILD / ILLUSTRATION M2777S....6335
The presence of an adequate lubricant coating guarantees:....6335
Maintenance....6336
Note....6336
Special attention must be given to the following types of damage and wear:....6336
Warning....6337
Detailed Explanation....6337
Cracked or Missing Link plates....6337
ILLUSTRATION / BILD / ILLUSTRATION M2774S....6337
Pitting and Corrosion....6337
ILLUSTRATION / BILD / ILLUSTRATION M2773S....6337
Protruding or Turned Pins....6338
Warning....6338
ILLUSTRATION / BILD / ILLUSTRATION M2776S....6338
Free Movement and Edge Wear....6338
ILLUSTRATION / BILD / ILLUSTRATION M2775S....6339
Chain Length Measurement....6339
ILLUSTRATION / BILD / ILLUSTRATION M2771S....6339
Chain Tension....6340
Chain Anchors and Pulleys....6340
FORK INSPECTION....6341
General....6341
Fork Identification....6341
WARNING....6341
Repairs....6342
Visual Inspection for Cracks....6342
WARNING....6342
Fig. M0346....6342
Fig. M0348....6342
Fig. M0347....6342
Straightness InspectionFig. M0350/0351/0349....6343
Fork Blade Bending Fig. M0352, Fig. M0353....6343
Inspection of Fork Tip Thickness Fig. M0355....6343
Fork Blade Height Difference Fig. M0354....6344
Fork Locking Fig. M0356....6344
Wear....6344
Fig. M0357....6345
Fig. M0358/0359....6345
Fig. M0360....6345
HYDRAULIC CYLINDER....6347
General....6347
WARNING....6347
Simplex mast cylinder....6347
Disassembly....6347
Lifting cylinder....6348
Disassembly....6348
PANELS, COVERS....6349
General....6349
Protective cover....6349
Disassembly....6349
Assembly....6349
Battery cover....6349
Disassembly....6349
Assembly....6349
Nuckle cover....6350
Disassembly....6350
Assembly....6350
Nuckle cover adjustment....6350
ILLUSTRATION / BILD / ILLUSTRATION M0436....6350
Folding Platform M1550....6352
Mechanical Setting ....6353
M1550....6354
Platform Switch Setting (PLS)....6355
Platform Suspension....6356
Plate Spring Layers....6356
MS1720-101....6356
ELECTRICAL DIAGRAMS....6357
WE/WS 2300 STANDARD SCHEMATIC DIAGRAM 813488....6357
WE/WS 2300 STANDARD DISTRIBUTION PANEL 813488-2A....6358
WE/WS 2300 STANDARD TRACTION CONTROLLER - POWER SIDE 813488-3A....6359
WE/WS 2300 STANDARD BRAKE CIRCUIT 813488-4A....6360
WE/WS 2300 STANDARD INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 813488-5A....6361
WE/WS 2300 STANDARD CONTROL HANDLE CIRCUIT 813488-6A....6362
WE/WS 2300 OPTION SCHEMATIC DIAGRAM 813489-1A....6363
WE/WS 2300 OPTION DISTRIBUTION PANEL 813489-2A....6364
WE/WS 2300 OPTION TRACTION CONTROLLER - POWER SIDE 813489-3A....6365
WE/WS 2300 BRAKE CIRCUIT OPTION 813489-4A....6366
WE/WS 2300 OPTION INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 81348_2A_5....6367
WE/WS 2300 OPTION CONTROL HANDLE CIRCUIT 813489_2A_6....6368
WE2300S / WS2300S STANDARD SCHEMATIC DIAGRAM 813519_2A_1....6369
WE2300S / WS2300S STANDARD DISTRIBUTION PANEL 813519_2A_2....6370
WE2300S / WS2300S STANDARD TRACTION CONTROLLER - POWER SIDE 813519_2A_3....6371
WE2300S / WS2300S STANDARD BRAKE CIRCUIT 813519_2A_4....6372
WE2300S / WS2300S STANDARD WALKIE / RIDER CIRCUIT 813519_2A_5....6373
WE2300S / WS2300S STANDARD INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 813519_2A_6....6374
WE2300S / WS2300S STANDARD CONTROL HANDLE CIRCUIT 813519_2A_7....6375
WE2300S / WS2300S OPTION SCHEMATIC DIAGRAM 813520_2A_1....6376
WE2300S / WS2300S OPTION DISTRIBUTION PANEL 813520_2A_2....6377
WE2300S / WS2300S OPTION TRACTION CONTROLLER - POWER SIDE 813520_2A_3....6378
WE2300S / WS2300S OPTION BRAKE CIRCUIT 813520_2A_4....6379
WE2300S / WS2300S OPTION WALKIE / RIDER CIRCUIT 813520_2A_5....6380
WE2300S / WS230 OPTION INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 813520_2A_6....6381
WE2300S / WS2300S OPTION CONTROL HANDLE CIRCUIT 813520_2A_7....6382
POWER CABLES 803466_2D_1....6383
Global Handle Harness 813426_2B_1 ....6384
Horn Harness 811931_2B_1....6385
Main Harness 803459_2G_1....6386
Main Harness....6387
Brake Harness....6388
Platform Harness....6389
Interface Connector 813472_2A_1....6390
WE/WS TL M0440....6391
HYDRAULIC SCHEMATIC....6391
WE/WS TF, WE/WS TT M0441....6392
WS Hydraulic Accessories TL Mast M1996....6393
WS Hydraulic Accessories TT Mast M1997....6394
WE_WS2300....6395
WE/WS 2300 SERIES....6395
Table of Contents....6397
Safety....6399
Introduction....6399
Lubrication & Adjustment....6399
Hydraulic System....6400
Drive Unit....6401
Electrical System....6401
Brake System....6406
Steering....6406
Lifting Mechanism....6407
Cylinders....6408
Platform....6408
Schematic Diagrams....6408
Hydraulic Schematic....6411
Safety....6413
Symbols Used....6415
Safety Symbols....6415
General Symbols....6415
Fork direction....6415
General Safety Instructions....6416
Maintenance and Repair Instructions....6416
Maintenance and Repairs....6416
Before Parking the Truck....6416
Before Working on the Truck....6416
Before Starting the Truck....6416
Warning and Instruction Decals on the Truck....6416
Introduction....6419
General....6421
Operator Manual....6421
Service Training....6421
Ordering Spare Parts....6421
Using the Manual....6421
Models....6422
Lubrication & Adjustment....6423
Component Access....6425
Drive Unit Cover....6425
Control Handle....6425
Control Handle Knuckle....6425
Mast....6425
Platform and Side Restraints(2)....6425
Component Access....6427
Drive Unit Cover....6427
Control Handle....6427
Control Handle Knuckle....6427
Mast....6427
Platform and side restraints(2)....6427
Lifting the Truck....6429
Lifting with a Crane....6429
Lifting with a Forklift Truck....6430
Towing the Truck....6431
Jacking up the Truck....6432
Service....6433
Recommended Lubricants....6433
Cold Store Trucks....6433
Taking the Truck out of Service....6433
Returning the Truck to Service....6433
Recommended Lubricants and Consumables....6434
Inspection and Maintenance Schedule....6436
Daily or Every 8 Service Hours....6437
Safety Reverse Switch Test....6439
Test and Maintenance Interval Chart....6440
Load Wheels and Castors....6446
Single Load Wheel Replacement (WE)....6446
Removal....6446
Assembly....6446
Tandem Load Wheel Replacement (WE)....6446
Removal....6446
Assembly....6447
Tandem Load Wheel Replacement (WS)....6447
Removal....6447
Assembly....6447
Castor (WE/WS)....6448
Removal....6448
Assembly....6448
Castor (WE-S/WS-S)....6449
Removal....6449
Assembly....6449
Castor Suspension (WE/WS)....6450
Removal....6450
Assembly....6450
Castor Suspension (WE-S/WS-S)....6451
Removal....6451
Assembly....6451
Torques....6452
Standard Torques....6452
Hydraulic System....6453
Hydraulic Schematic Symbols....6455
General Principles....6459
Hydraulic Lines and Ports....6459
Bleeding the Hydraulic System....6459
Drift Test....6459
Lifting:....6459
Pump Unit....6460
Removal....6460
Assembly....6461
Reservoir....6462
Removal....6462
Assembly....6462
Bleeding the Manifold....6462
Replacing the Filter....6463
Removal....6463
Assembly....6463
Valve Block....6464
Removal....6464
Assembly....6464
Valve Block....6464
Relief Valve....6465
Removal....6465
Assembly....6465
Relief Valve Setting....6465
Relief Valve Test and Setting....6465
Hydraulic Pump....6466
Removal....6466
Assembly....6466
Hydraulic System Troubleshooting....6467
Drive Unit....6469
Drive Wheel....6471
Removal....6471
Assembly....6471
Drive Unit Removal and Assembly....6472
Removal....6472
Assembly....6472
Gear Unit....6473
Removal....6473
Assembly....6473
Repairing the Gear Unit....6475
Preparation....6475
Dismantling....6475
Assembly....6475
Adjusting the bevel gear set....6476
Checking the flank tooth bearing....6476
Oil Change....6479
Draining Oil....6479
Adding Oil....6479
Live Ring Bearing....6480
Removal....6480
Assembly....6480
Pivoting Carriage....6481
General....6481
Removal....6481
Assembly....6481
Adjusting the pivoting carriage....6481
WE Trucks....6481
WS Trucks....6481
Pivoting Carriage....6482
General....6482
Removal....6482
Assembly....6482
Adjusting the pivoting carriage....6482
WE Trucks....6482
WS Trucks....6482
Electrical System....6483
General....6485
Wire colour code....6485
Contact Symbol Abbreviations....6486
Electrical wiring diagrams....6488
Electrical Components....6490
Switch....6490
(ALM) Travel alarm....6490
(BBD) Battery connector....6490
(BDI) Unigage....6490
(BRK) Brake....6490
(BRS) Brake switch....6490
(Charger) On-board charger....6490
(Charger) On-board charger....6490
(EDS) Emergency Power Disconnect Switch....6490
(F/R Contactor) Direction contactor....6490
(DR) Travel alarm driver....6490
(FU) Fuses....6490
(GCSR) Gate closed switch right....6490
(GCSR) Gate closed switch right....6491
(GCSL) Gate closed switch left....6491
(GCSL) Gate closed switch left....6491
(HCM) Hydraulic control module....6491
(HM) Horn....6491
(HNS) Horn switch....6491
(HSS) “Rabbit/Turtle” toggle switch....6491
(HYD PCB) Hydraulic printed circuit board....6491
(KYS) Key switch....6491
(LMS) Limit switch....6491
(LMS2) Limit switch....6491
(MAIN PCB) Main circuit board....6491
(M2) Pump motor....6491
(ORS) Override switch....6491
(P) Pump contactor....6492
(PC) Plug holder....6492
(PC) Plug holder....6492
(PCB) Distributor PCB....6492
(PLM) Platform logic....6492
(PLS) Platform switch....6492
(PLS) Platform switch....6492
(PM / M2) Hydraulic motor....6492
(POT, FS, RS) Traction pod....6492
(PV) Proportional valve....6493
(RAS, LOS1, LOS2) Raise / lower switches....6493
Safety reverse switch (SAS)....6493
(SLS / SRS) Aux. hydraulics switch....6493
SVH Toggle valve....6493
(SVA1 / SVA2) Aux. hydraulics valves....6493
(THS) Motor thermal switch....6493
(TM / M1) Traction motor....6493
Component Assembly Locations....6494
From serial no. 5A134882....6497
From serial no. 5A134882....6498
From serial no. 5A134882....6499
Traction Controller 1207....6500
Functions....6500
Key switch....6500
Current limit....6500
Overvoltage protection....6500
Overtemperature protection....6500
Performance reduction for low voltage....6500
Fault identification....6500
Error log....6500
Service....6501
Control Panel....6502
Adjusting potentiometer....6502
Programmer connection....6502
Status LED....6502
Diagnostics with the status LED....6502
Traction Controller Error Messages....6503
Status LED....6503
Error Reset....6505
Test Procedure....6506
Pulse Monitor Trip Test (PMT)....6506
Equipment....6506
Test....6506
PMT Test Wiring Diagram....6507
1307 Programmer....6508
General....6508
Connection....6508
Operation....6508
General....6508
Key Functions....6510
SCROLL DISPLAY keys....6510
CHANGE VALUE keys....6510
MORE INFO key....6510
PROGRAM key....6510
TEST key....6511
DIAGNOSTIC key....6511
Key Combinations....6511
SPECIAL DIAGNOSTIC menu....6511
SPECIAL PROGRAM menu....6511
Clearing the error history....6511
Copying (cloning) controller settings....6511
Resetting to defaults....6511
Programmer self-test....6512
1311 Programmer....6513
General....6513
Operation....6513
Menus....6514
Main menu....6514
Program menu....6514
Monitor menu....6514
Error menu....6514
Functions....6514
Hand Held Unit Settings....6514
Traction Controller Settings....6515
WE 1.25t/WS 1.35t....6515
Traction Controller Type 1207-1115 Setting....6515
WE 1.25t/WS 1.35t Platform....6515
Traction Controller Type 1207-1144 Setting....6515
WE 1.6t/WS 1.8t/WS 1.4 t....6516
Traction Controller Type 1207-1115 Setting....6516
WE 1.4t Platform / WS 1.4t Platform....6516
Traction Controller Type 1207-1144 Setting....6516
Programmer Menus....6517
"Program" Menu....6517
“Test” Menu....6518
“Diagnostics” and “Special Diagnostics” Menus....6519
“Special Program” Menu....6520
BDI / TT....6521
Battery Discharge Indicator / Hourmeter....6521
Removal....6521
Servicing....6521
Assembly....6521
Battery Discharge Indicator (BDI)....6521
General....6521
Battery Discharge Indicator Setting (BDI)....6522
Calibration....6522
Functional Description....6523
Platform Logic Controller, Part No. 815043....6523
KYS Key Switch....6526
Removal....6526
Servicing....6526
Assembly....6526
Speed Limit Switch (LMS)....6527
Removal....6527
Assembly....6527
Speed Limit Switch on Mast (LMS2)....6527
Removal....6527
Assembly....6527
Brake Switch (BRS)....6528
Removal....6528
Assembly....6528
Override Switch (ORS)....6530
Removal....6530
Assembly....6530
Emergency Disconnect Switch (EDS)....6531
Removal....6531
Servicing....6531
Assembly....6531
On Board Charger....6532
General....6532
Battery Charging Phases....6532
First Phase (I1)....6532
Second Phase (P)....6532
Third Phase (U)....6532
Fourth Phase (I2)....6532
End of Normal Charging....6532
Special Charging Phases....6532
Compensating Charge....6532
Float Charge....6533
Partial Charging....6533
Charging Errors....6533
Green LED is not lit....6533
Possible Causes:....6533
Green LED flashing....6533
Possible Causes:....6533
Important Technical Data....6534
Replacing the Charger....6535
Removal / Assembly....6535
On Board Charger....6536
General....6536
Battery Charging Phases....6536
First Phase (I1)....6536
Second Phase (P)....6536
Third Phase (U)....6537
Fourth Phase (I2)....6537
End of normal charging....6537
Special Charging Phases....6537
Compensating Charge....6537
Float charge....6537
Partial charging....6537
Charging Errors....6539
Green LED not lit....6539
Possible Causes:....6539
Green LED flashing....6539
Possible Causes:....6539
Important Technical Data....6540
Replacing the Charger....6540
Removal / Assembly....6540
Motors....6541
General Maintenance Instructions....6541
Important Maintenance Instructions....6541
Traction Motor....6542
Servicing....6542
Removal....6542
Repairs....6543
Assembly....6544
Pump Motor....6545
Removal....6545
Assembly....6545
Maintenance....6546
Accessing brushes....6546
Armature (WE/WS 1.25 and 1.3)....6546
Armature (WE/WS 1.4, 1.6 and 1.8)....6546
Bearings....6546
Pump Motor....6547
Removal....6547
Assembly....6547
Maintenance....6547
Accessing brushes....6547
Brushes (WE/WS 1.25, 1.3)....6547
Brushes (WE/WS 1.4, 1.6, 1.8)....6547
Armatures (WE/WS 1.25, 1.3)....6547
Armature (WE/WS 1.4, 1.6, 1.8)....6548
Electrical Panel....6549
General....6550
Removal....6550
Assembly....6550
Electrical Panel....6551
General....6552
Removal....6552
Assembly....6552
Contactors....6553
Inspection....6553
Contacts....6553
Coils....6553
Springs....6553
Checking the coils....6553
Servicing....6554
Travel contactor, part no. 802815....6554
Dismantling....6554
Assembly....6555
Travel contactor, part no. 804226....6556
Dismantling....6556
Assembly....6556
Contactor Removal / Assembly....6558
Travel Contactor....6558
Removal....6558
Assembly....6558
Lift Contactor....6558
Removal....6558
Assembly....6558
Battery....6559
Removal & Installation....6559
Removal with a lifting device....6559
Assembly....6559
Removal using the optional battery rollers:....6559
Servicing the Battery....6559
General....6559
Battery Connector....6559
Removal....6559
Servicing....6559
Hydraulic Control Module (HCM)....6561
Brake System....6563
Brake Operation....6565
Repairing the Brake....6566
Removal....6566
Dismantling....6566
Assembly....6567
Assembly....6567
Brake Air Gap Adjustment....6568
Setting the Braking Distance....6569
Default setting....6569
Testing and Adjusting the Braking Distance....6570
Calculating the braking distance....6570
Steering....6571
Control Handle Return Springs....6573
Spring Tension Adjustment....6573
Spring Removal....6573
Assembly....6574
Cardan Joint....6575
Removal....6575
Assembly....6575
Steering Chain....6576
Removal....6576
Assembly....6576
Tensioning the steering chain....6576
Forward Travel....6577
Test and Adjustment....6577
Up to serial no. 5A134880:....6577
From serial no. 5A134882:....6577
Tiller Handle Components....6578
Main Components....6578
Tools required....6579
Hand Grip Shells....6579
Removal....6579
Assembly....6580
Switch Unit....6581
Removal....6581
Assembly....6581
“Rabbit/Turtle” Toggle Switch....6582
Removal....6582
Assembly....6582
Hydraulic PC Board....6582
Removal....6582
Assembly....6582
Main PC Board....6583
Removal....6583
Assembly....6583
Potentiometer....6584
Removal....6584
Assembly....6585
Safety Reverse Switch....6586
Removal....6586
Assembly....6587
Horn Switch....6587
Removal....6587
Assembly....6587
Hand grip....6588
Removal....6588
Assembly....6589
Auxiliary Hydraulics Switch....6589
Removal....6589
Assembly....6589
Lifting Mechanism....6591
Mast....6593
General....6593
Lifting Gear Minimum Capacity....6593
Removal....6593
Assembly....6593
Fork Carriage....6594
Removal....6594
Assembly....6594
Adjusting the fork carriage clearance....6594
Mast and fork carriage clearance setting example....6595
Mast Maintenance....6596
Greasing the Roller Tracks....6596
Mast rollers....6596
Removal....6596
Assembly....6596
Lift Chains....6597
Inspection....6597
Cleaning Methods....6597
Wear....6597
Freedom of Movement of Chain Links....6599
Chain Tension....6599
Chain Anchor and Pulleys....6599
Worn Connection Plates....6599
Protruding or Turned Chain Pins....6600
Corrosion....6600
Chain Lateral Wear....6600
Uneven Chain Tension....6600
Misaligned Lift Components....6600
Lift Chain Lubrication....6601
Separating Lift Chains....6602
Tools and Equipment Required....6602
Separation....6602
Forks....6603
General....6603
Terms....6603
Fork identification....6603
Repairs....6603
Checking the Forks....6604
Crack Inspection....6604
Heel area....6604
Welding seams....6604
Verticality Test....6605
Fork Blade Warping....6605
Measuring the Fork Tip Width....6605
Fork Tine Height Difference....6606
Fork Stop....6606
Fork Blade Wear....6606
Cylinders....6607
Seal Assembly....6609
General....6609
Safety When Working on Hydraulic Systems....6609
General Instructions for Repairing Hydraulic Components....6609
Rod Seal Assembly....6609
General....6609
Large Rod Seal Assembly....6610
Small Seal Rod Assembly....6610
Rod Seal Assembly, Sealing Lip First....6611
Cylinder Removal and Assembly....6612
TL Mast Lift Cylinder....6612
Seal Replacement....6612
Installing TL Mast Lift Cylinders....6613
TF Mast Lift Cylinders....6614
Removing the TF Mast Lift Cylinders....6614
Seal replacement....6614
Installing TF Mast Lift Cylinders....6615
TF Free Lift Cylinder....6616
Seal replacement....6616
Installing Carriage Cylinder....6617
Cylinder Bleeding and Flushing....6617
Bleeding - Mast Lift Cylinders....6617
Bleeding - Free Lift Cylinder (if applicable)....6617
Flushing - Mast Lift Cylinders and Free Lift Cylinders (if applicable)....6617
Drift Test....6618
Cylinder Shimming....6618
Lift Cylinder Shims....6618
Free Lift Cylinder Shims....6618
HYDRAULIC CYLINDERS....6619
General....6619
Simplex mast cylinder....6619
Removal....6619
Lift Cylinder....6619
Removal....6619
Platform....6621
Folding Platform....6623
Mechanical Adjustment....6623
Adjusting the Platform Switch (PLS)....6624
Platform Cushioning....6625
Layering the disk springs....6625
Side restraint....6625
Mechanical Adjustment....6625
Schematic Diagrams....6627
WE / WS up to serial no. 5A132186....6629
Schematic Diagram, Standard....6629
Distribution Panel, Standard....6631
Traction Controller - Power Side, Standard....6632
Brake Circuit, Standard....6633
Instrument & Proportional Electronic Circuit, Standard....6634
Control Handle Circuit, Standard....6635
Schematic Diagram, Options....6636
Distribution Panel, Options....6638
Traction Controller - Power Side, Options....6639
Brake Circuit, Options....6640
Instrument & Proportional Electronic Circuit, Options....6641
Control Handle Circuit, Options....6642
Schematic Diagram, Auxiliary Hydraulics....6643
Distribution Panel, Auxiliary Hydraulics....6645
Traction Controller, Auxiliary Hydraulics....6646
Brake Circuit, Auxiliary Hydraulics....6647
Instrument & Prop. Electronics & Sideshift Circuit....6648
Control Handle Circuit, Auxiliary Hydraulics....6649
Control Handle Wire Harness....6650
Connector housing....6650
Contact pins....6650
Horn Harness....6651
Connector housing....6651
Contact pins....6651
Main Harness, Standard....6652
Main Harness, Auxiliary Hydraulics....6653
Connector housing....6654
Contact pins....6654
Hourmeter Harness....6655
Connector housing....6655
Contact pins....6655
Harness, Brake....6656
Connector housing....6656
Contact pins....6656
Harness, Control Module....6657
Connector housing....6657
Contact pins....6657
Proportional Hydraulics Connector Lead, Standard....6658
Connector housing....6658
Contact pins....6658
Connector housing....6659
Contact pins....6659
Connector housing....6660
Contact pins....6660
Connector housing....6661
Contact pins....6661
Contact pins....6662
ORS Jumper....6663
Connector housing....6663
Contact pins....6663
Power Cables....6664
WE S / WS S up to serial no. 5A132186....6665
Schematic Diagram, Standard....6665
Distribution Panel, Standard....6666
Traction Controller - Power Side, Standard....6667
Brake Circuit, Standard....6668
Walkie / Rider Circuit, Standard....6669
Instrument & Proportional Electronic Circuit, Standard....6670
Control Handle Circuit, Standard....6671
Schematic Diagram, Option....6672
Distribution Panel, Option....6674
Traction Controller - Power Side, Option....6675
Brake Circuit, Option....6676
Walkie / Rider Circuit, Option....6677
Instrument & Proportional Electronic Circuit, Option....6678
Control Handle Circuit, Option....6679
Schematic Diagram, Auxiliary Hydraulics....6680
Distribution Panel, Auxiliary Hydraulics....6682
Traction Controller, Power Side, Auxiliary Hydraulics....6683
Brake Circuit, Auxiliary Hydraulics....6684
Walkie / Rider Circuit, Auxiliary Hydraulics....6685
Instrument & Prop. Electronics & Sideshift Circuit, Auxiliary Hydraulics....6686
Control Handle Circuit, Auxiliary Hydraulics....6687
Control Handle Harness....6688
Connector housing....6688
Contact pins....6688
Horn Harness....6689
Connector housing....6689
Contact pins....6689
Main Harness, Standard....6690
Main Harness, Auxiliary Hydraulics....6691
For tables for Fig. 807229_2D (see page 241)....6692
Connector housing....6692
Contact pins....6692
Hourmeter Harness....6693
Connector housing....6693
Contact pins....6693
Harness, Brake....6694
Connector housing....6694
Contact pins....6694
Harness, Control Module....6695
Connector housing....6695
Contact pins....6695
Proportional Hydraulics Connector Lead, Standard....6696
Connector housing....6696
Contact pins....6696
Connector housing....6697
Contact pins....6697
Connector housing....6698
Contact pins....6698
Connector housing....6699
Contact pins....6700
ORS Jumper....6701
Contact pins....6701
Harness 1, Platform....6702
Connector housing....6702
Contact pins....6702
Harness 2, Platform....6703
Connector housing....6703
Contact pins....6703
Power Cables....6704
WE / WS from serial no. 5A132188 to serial no. 5A134880....6705
Schematic Diagram, Standard....6705
Distribution Panel, Standard....6707
Traction Controller - Power Side, Standard....6708
Brake Circuit, Standard....6709
Walkie / Rider, Standard....6710
Instrument & Platform Logic, Standard....6711
Control Handle Circuit, Standard....6712
Schematic Diagram, Standard....6713
Traction Controller, Option....6716
Brake Circuit, Option....6717
Walkie / Rider Circuit, Option....6718
Instrument & Platform Logic, Option....6719
Control Handle Circuit, Option....6720
Schematic Diagram, Auxiliary Hydraulics....6722
Distribution Panel, Auxiliary Hydraulics....6724
Traction Controller - Power Side, Auxiliary Hydraulics....6725
Brake Circuit, Auxiliary Hydraulics....6726
Walkie / Rider Circuit & Instrument, Auxiliary Hydraulics....6727
Instrument & Prop. Electronics & Sideshift Circuit, Auxiliary Hydraulics....6728
Control Handle Circuit, Auxiliary Hydraulics....6729
Platform Logic, Auxiliary Hydraulics....6731
Control Handle Wire Harness....6732
Connector housing....6732
Contact pins....6732
Horn Harness....6733
Connector housing....6733
Contact pins....6733
Main Harness....6734
For tables for Fig. 815408_2E (see page 322)....6735
Connector housing....6735
Contact pins....6735
Cable lugs and rings....6735
Main Harness, Auxiliary Hydraulics....6736
For tables for Fig. 816076_2B (see page 324)....6737
Connector housing....6737
Contact pins....6737
Hourmeter Harness....6738
Connector housing....6738
Contact pins....6738
Harness, ORS - BRS - BRK....6739
Connector housing....6739
Contact pins....6739
Harness, TCM....6740
Connector housing....6740
Contact pins....6740
Proportional Hydraulics Connector Lead, Standard....6741
Connector housing....6741
Contact pins....6741
Connector housing....6742
Contact pins....6742
Connector housing....6743
Contact pins....6743
Connector housing....6744
Contact pins....6745
ORS Jumper....6746
Contact pins....6746
Harness, Platform Logic....6747
For tables for Fig. 815374_2H (see page 335)....6748
Connector housing....6748
Contact pins....6748
Platform Cable 1....6749
Connector housing....6749
Contact pins....6749
Platform Cable 2....6750
Connector housing....6750
Contact pins....6750
Cable, LMS2....6751
Connector housing....6751
Contact pins....6751
WE / WS from serial no. 5A134882....6752
Schematic Diagram, Standard....6752
Distribution Panel, Standard....6754
Traction Controller - Power Side, Standard....6755
Brake Circuit, Standard....6756
Instrument & Proportional Electronic Circuit, Standard....6757
Control Handle Circuit, Standard....6758
Option Connection, Thermal Switch, Standard....6760
Schematic Diagram, Options....6761
Distribution Panel, Options....6763
Traction Controller - Power Side, Options....6764
Brake Circuit, Options....6765
Instrument & Proportional Electronic Circuit, Options....6766
Control Handle Circuit, Options....6767
Option Connection, Thermal Switch, Options....6769
Control Handle Wire Harness....6770
Connector housing....6770
Contact pins....6770
Horn Harness....6771
Connector housing....6771
Main Harness....6772
For tables for Fig. 816836_2D_1 (see page 360)....6773
Connector housing....6773
Contact pins....6773
Cable lugs and rings....6773
Hourmeter Harness....6774
Connector housing....6774
Contact pins....6774
Strobe & Alarm Signal Optional Harness....6775
Connector housing....6775
Contact pins....6775
Cable lugs and rings....6775
Strobe & Alarm Signal Optional Harness....6776
Connector housing....6777
Contact pins....6777
Mast Cable for Strobe Light....6778
Jumper 1.25 t....6778
Contact pins....6779
Power Cables....6780
Schematic Diagram, Standard....6781
Electric Diagram, Standard....6783
Traction Controller, Power Side, Standard....6784
Brake Circuit, Standard....6785
Instrument & Proportional Electronic Circuit, Standard....6786
Control Handle Circuit, Standard....6787
PLM - Platform Logic Module, Walkie / Rider Circuit....6788
Option Connection, Thermal Switch, Standard....6790
Schematic Diagram, Standard....6791
Distribution Panel, Options....6793
Traction Controller - Power Side, Options....6794
Brake Circuit, Options....6795
Instrument & Proportional Electronic Circuit, Options....6796
Control Handle Circuit, Options....6797
PLM - Platform Logic Module, Walkie / Rider Circuit, Options....6799
Option Connection, Thermal Switch, Options....6801
Control Handle Wire Harness....6802
Connector housing....6802
Contact pins....6802
Horn Harness....6803
Connector housing....6803
Main Harness....6804
Connector housing....6805
Contact pins....6805
Cable lugs and rings....6805
Hourmeter Harness....6806
Connector housing....6806
Contact pins....6806
Strobe & Alarm Signal Optional Harness....6807
Connector housing....6807
Contact pins....6807
Cable lugs and rings....6807
Strobe & Alarm Signal Optional Harness....6808
Connector housing....6809
Contact pins....6809
Mast Cable for Strobe Light....6810
Jumper 1.25 t....6810
Contact pins....6811
ORS Jumper....6812
Contact pins....6812
Platform Cable 2....6813
Connector housing....6813
Contact pins....6813
Cable, LMS2....6814
Connector housing....6814
Contact pins....6814
Power Cables....6815
Hydraulic Schematic....6817
Hydraulic Diagrams....6819
WE/WS TL....6819
WE/WS TF....6820
WE/WS TT....6820
WS Auxiliary Hydraulics TL Mast....6821
WS Auxiliary Hydraulics TT Mast....6822
TL Mast....6823
Abbreviations....6823
TT mast....6824
Abbreviations....6824
TF mast....6825
Abbreviations....6825
WF3000....6827
WF3000....6828
WF3000....6828
REVISION....6830
SAFETY....6844
Safety Symbols used in the Manual....6844
Maintenance and Repair....6844
Warnings and Labels on the Truck....6845
INTRODUCTION....6848
General....6848
Model-Number....6849
LUBRICATION AND ADJUSTMENT....6852
Raising And Towing The Truck....6852
Component Access....6855
Maintenance....6857
Recommended Lubricants and Oils....6857
Lubricant Table....6858
Adjuvants Table....6859
Truck Tilt Settings....6863
Testing and Adjusting the Lateral Inclination....6863
Lowering Plumb Test....6863
HYDRAULICS....6868
Hydraulic Symbols....6868
Hydraulics....6872
Hydraulic Reservoir Capacity....6872
Changing the Hydraulic oil and Hydraulic Filter....6872
Hydraulic system....6874
Function....6874
MOTOR AND PUMP ASSEMBLY....6876
REMOVAL....6876
MOTOR....6877
PUMP....6877
Replacing the relief valve....6878
Relief valve test and setting....6878
Hydraulic System Troubleshooting....6879
DRIVE UNIT....6882
Drive unit, general....6883
Drive unit removal....6883
Drive motor removal....6883
Motor disassembly....6884
Motor assembly....6884
Drive motor assembly....6886
Gear unit disassembly....6887
Gear unit assembly....6888
Adding Oil....6890
Drive unit installation....6890
ELECTRICS....6894
Electrics - General....6894
Wire Colour Codes....6894
Abbreviations....6895
Electrical Symbols....6898
Electrical Components....6899
SEM0 Traction Controller....6905
Maintenance....6907
Replacing the SEM0 Traction Controller....6908
Parameter Setting after Replacing the Traction Controller....6908
Status LED....6910
Programmer....6911
Operating SEM0 Controller Menu....6912
Menu Functions....6913
Functions Menu, general....6914
Parameter Change Menus....6915
Settings and Error Messages....6916
Tester Menu....6921
Alarms Menu....6923
ALARMS Menu....6924
Calibrating the Traction Pod....6927
Config. Menu....6928
CONFIG Menu....6929
On Board Charger....6930
Charging Errors....6932
Replacing the Charger....6933
Electric Motors....6934
Traction Motor Maintenance (WF 1.0 t)....6935
Traction Motor Maintenance (WF 1.2 t)....6936
Pump Motor Maintenance....6937
Contactors....6938
Hydraulic Control Module (HCM)....6940
Battery Discharge Indicator (BDI)....6941
Battery Discharge Indicator Setting....6942
Calibration for wet batteries....6943
TROUBLESHOOTING....6944
Traction Controller Safety Test....6945
BRAKE....6948
Air gap setting....6950
Brake test....6951
STEERING....6956
Live ring bearing....6956
Control handle return springs....6957
Steering Chain....6958
Tiller Handle....6960
MAST....6972
Mast Removal....6972
Installation....6973
Fork Carriage Removal....6973
Fork Carriage Installation....6973
Fork Carriage Adjustment....6974
Mast Maintenance....6975
Lowering Plumb Test....6976
Lift chains....6977
Fork Tines....6983
CYLINDERS....6988
Rod Seal Assembly....6989
TL Mast Lift Cylinder....6992
TF Mast Lift Cylinders....6995
Free Lift Cylinder TF and Mono Mast....6997
Cylinder Bleeding and Flushing....6998
Cylinder Shimming....6999
DIAGRAMS....7004
WF 3000-10 Standard....7004
WF3000-10 with Options....7010
WF 3000-12 Standard....7016
WF3000-12 with Options....7022
Wire Harness....7028
Control handle Wiring....7029
Power Cables....7030
HYDRAULIC CIRCUIT....7034
Hydraulik Schematic Standard Lift....7034
Hydraulik Schematic Soft Lift....7035
WP....7036
14245585-Crown_Wp2300s_Series_Forklift_Service_Repair_Manual.pdf.ppg28na....7037
WP2300S....7037
REVISION....7039
Overview of Revisions:....7039
TABLE OF CONTENT....7043
SAFETY....7051
Safety Symbols used in the Manual....7051
General Maintenance and Repair Safety Notes....7051
Maintenance and Repair....7051
Before Leaving the Truck....7052
Before Carrying out Work on the Truck....7052
Before Operating the Truck....7052
Warnings and Labels on the Truck....7052
INTRODUCTION....7055
General....7055
Operating Instructions....7055
Service Training....7055
Ordering Spare Parts....7055
Using the Manual....7055
Model-Number....7056
LUBRICATION AND ADJUSTMENT....7059
Jacking up the Truck....7059
Raising the Truck with a Crane....7059
Fixed Platform....7059
Folding Platform....7060
Both Platforms....7061
Raising with a Forklift Truck....7062
Component Access and Components....7063
Maintenance....7066
Recommended Lubricants and Oils....7066
Lubricants....7066
Cold Store Trucks....7066
Truck Decommissioning....7066
Restoring the Truck to Service....7066
Lubricant Type, Product Description, Manufacturer, CROWN-Part-No., Type....7067
Product, Product Name, Application, Crown Part No....7067
Check and Maintenance Schedule....7068
Daily or every 8 service hours....7068
Safety Reverse Switch – Functional Test....7070
Monthly or every 100 service hours....7072
Every 3 months or 250 service hours....7074
Every 6 months or 500 service hours....7074
Annually or every 1000 service hours....7076
Every 2 years or 2000 service hours....7076
Grease items and grease intervals....7078
Adjusting the Contact Pressure of the Castors and the Drive Wheel....7080
Torques....7081
Screw grade marking. Nut grade marking....7081
Standard Screws and Nuts....7082
Umbrako Screws and Nuts....7082
HYDRAULICS....7085
Hydraulic Symbols....7085
Hydraulic System....7089
Operation....7089
Removing the Hydraulic Unit....7090
Replacing the Hydraulic Pump....7091
Removal....7091
Installation....7091
Commissioning and Bleeding the System....7091
Pump Motor....7093
Filters....7093
Replacing the Pressure Filter....7093
Replacing the Suction and Return Filters....7093
Oil Change....7093
Replacing the Safety Valve....7094
Safety Valve Setting....7094
Safety Valve Test and Setting....7094
Testing and Setting the Load- Dependent Pressure Switch....7095
DRIVE UNIT....7099
Gear Unit....7099
Preparatory Measures....7099
Removal....7099
Maintenance....7099
General....7099
Gear Unit Disassembly / Assembly....7101
Disassembly....7101
Assembly....7101
Preparing the Gear Unit....7101
Flange Shaft Assembly....7101
Pinion Shaft Assembly....7102
Adjusting the Bevel Gear Assembly....7102
Final Assembly....7102
Assembly....7103
Drive Motor....7103
ELECTRICS....7107
Electrics - General....7107
Wire Colour Codes....7107
Abbreviations....7108
Switch Symbol Abbrevation List....7108
Sunrdy Abbrevations....7109
Other Abbrevations....7110
Electrical Symbols....7110
Electrical Components....7111
Travel Switch (POT, FS, RS)....7111
Fast/Slow Switch (HSS)....7111
Safety Reverse Switch (SAS)....7111
Brake Switch (BRS)....7111
Raise/Lower Switch (RAS, LOS)....7111
Pressure Switch (PS)....7111
Platform Control Switches (GCSR, GCSL, PLS)....7112
Lift Limit Switch (LMS)....7112
Horn Switch (HNS)....7112
Foot Switch (FTS)....7112
Key Switch (KYS)....7112
Emergency Disconnect (BD)....7112
Fuses (FU)....7112
Thermal Switch (THS)....7112
Battery....7115
General....7115
Replacing the battery....7115
Battery Discharge Indicator (BDI)....7115
General....7115
Battery Discharge Indicator Setting (BDI)....7116
Calibration....7116
Discharge Terminal Voltage Setting in Volts/Cell....7116
SEM1 Traction Controller....7117
General....7117
Precautionary Measures....7117
Operational Features....7117
Speed Control....7117
Reduced Speed Ranges....7117
Downhill Speed Control....7117
Regenerative Braking....7117
Anti - Roll Down Function....7117
Hourmeter....7118
Self Test....7118
Monitored Circuits....7118
Protective Devices....7118
Polarity Protection....7118
Wiring Errors....7118
Temperature....7118
Start Sequence....7118
Safety Class....7118
Maintenance....7119
Replacing the SEM1 Traction Controller....7120
Parameter Setting after Replacing the Traction Controller....7120
Preparatory Measures....7120
Setting....7120
Status LED....7122
No. of Flashes, Console Display, Notes....7122
Programmer....7123
General....7123
Description of Keys....7124
Operating SEM1 Controller Menu....7124
General....7124
Menu Functions....7124
Menu Structure for Folded Platform....7125
Menu Structure for Fixed Platform....7126
Parameter Setting, Folded Platform....7127
PARAMETER CHANGE Menu, folded platform, SW#006B....7127
PARAMETER CHANGE Menu, folded platform, SW#006B....7128
Parameter Setting, Fixed Platform....7128
PARAMETER CHANGE Menu, fixed platform, SW#0105....7128
PARAMETER CHANGE Menu, fixed platform, SW#105....7129
TESTER Menu....7130
ALARMS Menu....7131
ALARMS Menu (Contd.)....7132
ALARMS Menu (Contd.)....7133
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu....7134
Preparatory Measures....7134
Calibration....7134
CONFIG Menu....7135
SET MODEL....7135
SET OPTIONS....7135
ADJUSTMENTS....7135
Traction Controller Safety Test....7136
Electric Motors....7137
General Maintenance Instructions....7137
Preparation....7137
Important Maintenance Instructions....7137
Traction Motor Maintenance....7138
Access to Brushes....7138
Maintenance....7138
Armature....7138
Bearings....7138
Pump Motor Maintenance....7139
Access to brushes....7139
Maintenance....7139
Armature....7139
BRAKE....7143
Removal....7143
Disassembly....7144
Test and Inspection....7144
Assembly....7144
Assembly....7145
Air Gap Setting....7145
Brake Moment Setting....7146
Testing the Brakes....7146
WP2300S Nominal Braking Distances and Screw Depth....7146
STEERING....7149
Multitask Handle - Springs for Return Function....7149
Adjustment....7149
Removal....7149
Assembly....7149
Tiller Handle....7151
Main Components....7151
Tiller Handle Component Removal / Installation....7152
Tiller Handle Shells....7152
Removing the Upper and Lower Shells....7152
Fitting the Upper and Lower Shells....7153
Switch Unit....7154
Removal....7154
Switch Unit Installation....7154
"Fast/Slow" Toggle Switch....7155
Removal....7155
Installation....7155
Hydraulic Board....7155
Removal....7155
Installation....7155
Potentiometer....7156
Removal....7156
Installation....7156
Safety Reverse Switch....7157
Removal....7157
Installation....7157
Horn Switch....7158
Removal....7158
Installation....7158
Handle....7159
Removal....7159
Installation....7159
LIFTING MECHANISM....7163
Lift Linkage....7163
Fork Height Setting....7163
Lift Limit Cutout....7165
Lift Limit Cutout Setting....7165
CYLINDERS....7169
Lift Cylinders....7169
Operation....7169
Removal....7169
Inspection....7171
Replacing the Piston Seal....7171
PLATFORM....7175
Folding Platform....7175
Mechanical Setting....7175
Platform Switch Setting (PLS)....7176
Platform Suspension....7177
Plate Spring Layers....7177
Side Gates, Mechanical Setting....7178
Fixed Platform....7179
Replacing the Deadman Switch....7179
DIAGRAMS....7183
Overall Wiring Diagram, Standard, Folded Platform....7183
Overall Wiring Diagram, Folded Platform with Options....7184
Overall Wiring Diagram, Standard, Fixed Platform....7185
Overall Wiring Diagram, Fixed Platform with Options....7186
Wire harness overview, folded platform, all versions....7187
Wire harness overview, fixed platform, all versions....7188
Power Cables....7189
HYDRAULIC CIRCUIT....7193
Crown_Wp2300s_Series_Forklift_Service_Repair_Manual.pdf.ppg28na....7195
WP2300S....7195
REVISION....7197
Overview of Revisions:....7197
TABLE OF CONTENT....7201
SAFETY....7209
Safety Symbols used in the Manual....7209
General Maintenance and Repair Safety Notes....7209
Maintenance and Repair....7209
Before Leaving the Truck....7210
Before Carrying out Work on the Truck....7210
Before Operating the Truck....7210
Warnings and Labels on the Truck....7210
INTRODUCTION....7213
General....7213
Operating Instructions....7213
Service Training....7213
Ordering Spare Parts....7213
Using the Manual....7213
Model-Number....7214
LUBRICATION AND ADJUSTMENT....7217
Jacking up the Truck....7217
Raising the Truck with a Crane....7217
Fixed Platform....7217
Folding Platform....7218
Both Platforms....7219
Raising with a Forklift Truck....7220
Component Access and Components....7221
Maintenance....7224
Recommended Lubricants and Oils....7224
Lubricants....7224
Cold Store Trucks....7224
Truck Decommissioning....7224
Restoring the Truck to Service....7224
Lubricant Type, Product Description, Manufacturer, CROWN-Part-No., Type....7225
Product, Product Name, Application, Crown Part No....7225
Check and Maintenance Schedule....7226
Daily or every 8 service hours....7226
Safety Reverse Switch – Functional Test....7228
Monthly or every 100 service hours....7230
Every 3 months or 250 service hours....7232
Every 6 months or 500 service hours....7232
Annually or every 1000 service hours....7234
Every 2 years or 2000 service hours....7234
Grease items and grease intervals....7236
Adjusting the Contact Pressure of the Castors and the Drive Wheel....7238
Torques....7239
Screw grade marking. Nut grade marking....7239
Standard Screws and Nuts....7240
Umbrako Screws and Nuts....7240
HYDRAULICS....7243
Hydraulic Symbols....7243
Hydraulic System....7247
Operation....7247
Removing the Hydraulic Unit....7248
Replacing the Hydraulic Pump....7249
Removal....7249
Installation....7249
Commissioning and Bleeding the System....7249
Pump Motor....7251
Filters....7251
Replacing the Pressure Filter....7251
Replacing the Suction and Return Filters....7251
Oil Change....7251
Replacing the Safety Valve....7252
Safety Valve Setting....7252
Safety Valve Test and Setting....7252
Testing and Setting the Load- Dependent Pressure Switch....7253
DRIVE UNIT....7257
Gear Unit....7257
Preparatory Measures....7257
Removal....7257
Maintenance....7257
General....7257
Gear Unit Disassembly / Assembly....7259
Disassembly....7259
Assembly....7259
Preparing the Gear Unit....7259
Flange Shaft Assembly....7259
Pinion Shaft Assembly....7260
Adjusting the Bevel Gear Assembly....7260
Final Assembly....7260
Assembly....7261
Drive Motor....7261
ELECTRICS....7265
Electrics - General....7265
Wire Colour Codes....7265
Abbreviations....7266
Switch Symbol Abbrevation List....7266
Sunrdy Abbrevations....7267
Other Abbrevations....7268
Electrical Symbols....7268
Electrical Components....7269
Travel Switch (POT, FS, RS)....7269
Fast/Slow Switch (HSS)....7269
Safety Reverse Switch (SAS)....7269
Brake Switch (BRS)....7269
Raise/Lower Switch (RAS, LOS)....7269
Pressure Switch (PS)....7269
Platform Control Switches (GCSR, GCSL, PLS)....7270
Lift Limit Switch (LMS)....7270
Horn Switch (HNS)....7270
Foot Switch (FTS)....7270
Key Switch (KYS)....7270
Emergency Disconnect (BD)....7270
Fuses (FU)....7270
Thermal Switch (THS)....7270
Battery....7273
General....7273
Replacing the battery....7273
Battery Discharge Indicator (BDI)....7273
General....7273
Battery Discharge Indicator Setting (BDI)....7274
Calibration....7274
Discharge Terminal Voltage Setting in Volts/Cell....7274
SEM1 Traction Controller....7275
General....7275
Precautionary Measures....7275
Operational Features....7275
Speed Control....7275
Reduced Speed Ranges....7275
Downhill Speed Control....7275
Regenerative Braking....7275
Anti - Roll Down Function....7275
Hourmeter....7276
Self Test....7276
Monitored Circuits....7276
Protective Devices....7276
Polarity Protection....7276
Wiring Errors....7276
Temperature....7276
Start Sequence....7276
Safety Class....7276
Maintenance....7277
Replacing the SEM1 Traction Controller....7278
Parameter Setting after Replacing the Traction Controller....7278
Preparatory Measures....7278
Setting....7278
Status LED....7280
No. of Flashes, Console Display, Notes....7280
Programmer....7281
General....7281
Description of Keys....7282
Operating SEM1 Controller Menu....7282
General....7282
Menu Functions....7282
Menu Structure for Folded Platform....7283
Menu Structure for Fixed Platform....7284
Parameter Setting, Folded Platform....7285
PARAMETER CHANGE Menu, folded platform, SW#006B....7285
PARAMETER CHANGE Menu, folded platform, SW#006B....7286
Parameter Setting, Fixed Platform....7286
PARAMETER CHANGE Menu, fixed platform, SW#0105....7286
PARAMETER CHANGE Menu, fixed platform, SW#105....7287
TESTER Menu....7288
ALARMS Menu....7289
ALARMS Menu (Contd.)....7290
ALARMS Menu (Contd.)....7291
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu....7292
Preparatory Measures....7292
Calibration....7292
CONFIG Menu....7293
SET MODEL....7293
SET OPTIONS....7293
ADJUSTMENTS....7293
Traction Controller Safety Test....7294
Electric Motors....7295
General Maintenance Instructions....7295
Preparation....7295
Important Maintenance Instructions....7295
Traction Motor Maintenance....7296
Access to Brushes....7296
Maintenance....7296
Armature....7296
Bearings....7296
Pump Motor Maintenance....7297
Access to brushes....7297
Maintenance....7297
Armature....7297
BRAKE....7301
Removal....7301
Disassembly....7302
Test and Inspection....7302
Assembly....7302
Assembly....7303
Air Gap Setting....7303
Brake Moment Setting....7304
Testing the Brakes....7304
WP2300S Nominal Braking Distances and Screw Depth....7304
STEERING....7307
Multitask Handle - Springs for Return Function....7307
Adjustment....7307
Removal....7307
Assembly....7307
Tiller Handle....7309
Main Components....7309
Tiller Handle Component Removal / Installation....7310
Tiller Handle Shells....7310
Removing the Upper and Lower Shells....7310
Fitting the Upper and Lower Shells....7311
Switch Unit....7312
Removal....7312
Switch Unit Installation....7312
"Fast/Slow" Toggle Switch....7313
Removal....7313
Installation....7313
Hydraulic Board....7313
Removal....7313
Installation....7313
Potentiometer....7314
Removal....7314
Installation....7314
Safety Reverse Switch....7315
Removal....7315
Installation....7315
Horn Switch....7316
Removal....7316
Installation....7316
Handle....7317
Removal....7317
Installation....7317
LIFTING MECHANISM....7321
Lift Linkage....7321
Fork Height Setting....7321
Lift Limit Cutout....7323
Lift Limit Cutout Setting....7323
CYLINDERS....7327
Lift Cylinders....7327
Operation....7327
Removal....7327
Inspection....7329
Replacing the Piston Seal....7329
PLATFORM....7333
Folding Platform....7333
Mechanical Setting....7333
Platform Switch Setting (PLS)....7334
Platform Suspension....7335
Plate Spring Layers....7335
Side Gates, Mechanical Setting....7336
Fixed Platform....7337
Replacing the Deadman Switch....7337
DIAGRAMS....7341
Overall Wiring Diagram, Standard, Folded Platform....7341
Overall Wiring Diagram, Folded Platform with Options....7342
Overall Wiring Diagram, Standard, Fixed Platform....7343
Overall Wiring Diagram, Fixed Platform with Options....7344
Wire harness overview, folded platform, all versions....7345
Wire harness overview, fixed platform, all versions....7346
Power Cables....7347
HYDRAULIC CIRCUIT....7351
WP2000....7353
WP2000....7353
Table of Content....7356
IDX-1720-002....7357
IDX-1720-003....7358
SAFETY....7360
Safety Symbols used....7362
General Maintenance and Repair....7362
Maintenance and Repair....7362
Before Leaving the Truck....7363
Before Carrying out Work on the Truck....7363
INTRODUCTION....7364
General....7366
Operating Instructions....7366
Service Training....7366
Ordering Spare Parts....7366
Page Numbering in the Manual....7367
Truck Data Numbering Sheet....7369
LUBRICATION AND ADJUSTMENT....7370
Component Access....7372
Jacking up the Truck....7372
Lifting by Crane....7372
Lifting by Truck....7373
Components....7374
Maintenance....7377
Driver Participation....7377
Daily Maintenance Log....7377
Recommended Lubricants and Oils....7377
Lubricants....7377
Cold Store Trucks....7377
Table Lubricant Types....7378
Check and Maintenance Schedule....7379
Daily or every 8 hours....7379
Safety Reverse Switch - Functional Test....7381
Monthly or every 100 hours....7383
3 months or 250 hours....7385
6 months or 500 hours....7385
Annually or 1000 hours....7387
2 Years or 2.000 hours....7387
Grease items and grease intervals....7389
Castors....7391
Torques....7392
HYDRAULICS....7394
Symbols used....7394
Hydraulic System....7396
Operation....7396
Removal....7397
Filter....7398
Pressure Filter....7398
Suction and Return Filters....7398
Oil Change....7398
Hydraulic Pump....7399
Commissioning....7399
Pump Motor....7399
DRIVE UNIT....7400
Gear Unit....7402
Oil Change....7402
Gear Unit Assembly / Disassembly....7404
Drive Motor Disassembly....7404
Pinion Shaft Disassembly....7404
Driven Shaft Disassembly....7404
Driven Shaft Assembly....7404
Pinion Shaft Assembly....7404
Drive Motor Pre-Assembly....7405
Housing Lid Assembly....7405
Drive Motor Assembly....7405
Drive Unit Assembly....7405
Drive Motor....7405
ELECTRICS....7406
Electrics - General....7408
Wire Colour Codes....7408
Abbreviations....7409
Electrical Symbols....7411
Electrical Components....7412
Transmitter (POT, FS, RS)....7412
Fast / Slow Travel Switch (HSS)....7412
Reverse Safety Switch (SAS)....7412
Brake Switch (BRS)....7412
Override Switch (ORS)....7412
Handle Position and Functions....7412
Lift / Lower Switch (RAS, LOS)....7413
Limit Switch (LMS)....7413
Horn Switch (HNS)....7413
Key Switch (KYS)....7413
Emergency Disconnect....7413
Fuses (FU)....7413
Limit Switch Settings....7413
ZAPI SEM Zero Traction Controller....7414
General....7414
Precautionary Measures....7414
Operational Features....7414
Speed Control....7414
Reduced Speed Ranges....7414
Downhill Speed Control....7414
Regenerative Braking....7414
Anti - Roll Down Function....7414
Hourmeter....7415
Self Test....7415
Monitored Circuits....7415
Protective Devices....7415
Polarity Protection....7415
Wiring Errors....7415
Temperature....7415
Start Sequence....7415
Safety Class....7415
Maintenance....7416
SEM Zero Traction Controller Connections....7417
Programmer....7420
General....7420
Description of Keys....7421
Operating Menu ZAPI SEM Zero Con-troller....7421
Operating Menu - Overview....7422
Menu Functions....7422
PARAMETER CHANGE....7422
TESTER....7422
ALARMS....7422
PROGRAM VACC....7422
CONFIG....7422
Settings and Alarms....7423
TESTER Menu....7424
ALARMS Menu....7425
(Contd.) Menu ALARMS....7426
(Contd.) Menu ALARMS....7427
PROGRAM VACC Menu....7427
CONFIG Menu....7428
Power Connections....7417
Control Connections....7417
SEM Zero Pin Layout....7418
Status LED....7419
Traction Controller Safety Test....7429
Battery....7430
General....7430
Operation....7430
Reading the Electrolyte Level....7430
Charging the Battery....7431
Battery Discharge Indicator (BDI)....7432
General....7432
Adjusting the Battery Discharge Indicator....7432
Traction / Pump Motor Maintenance....7433
Access....7433
Maintenance....7433
BRAKE....7434
Operation....7436
Removal....7436
Assembly....7437
Air Gap Setting....7437
Brake Moment Setting....7437
Testing the Brakes....7437
STEERING....7438
Live Ring Bearing....7440
Multitask Handle - Springs for Return....7441
Adjustment....7441
Removal....7441
Assembly....7441
LIFTING MECHANISM....7442
CYLINDERS....7446
Lift Cylinders....7448
Operation....7448
Removal....7448
Inspection....7450
Replacing the Piston Seal....7450
ELECTRICAL DIAGRAMS....7452
Control Circuit....7454
Traction Controller....7455
Traction Controller....7456
Brake and Battery Discharge Indicator....7457
Handle Circuit....7458
Power Cables....7459
Control Circuit / Freezer Condition....7460
Traction Controller / Freezer Condition....7461
Traction Controller / Freezer Condition....7462
Brake and Battery Discharge Indicator / Freezer Condition....7463
Handle Circuit / Freezer Condition....7464
Power Cables / Freezer Condition....7465
Abbreviations....7466
Abbreviations....7467
HYDRAULIC SCHEMATIC....7470
WP2000S....7473
WP2000S....7473
TABLE OF CONTENT....7475
M-IDX-1720-501....7477
M-IDX-1720-502....7478
M-IDX-1720-503....7479
SAFETY....7481
Safety Symbols used in the Manual....7483
Manual General Maintenance and Repair Safety Notes....7483
Maintenance and Repair....7483
Before Leaving the Truck....7484
Before Carrying out Work on the Truck....7484
Before Operating the Truck....7484
Warnings and Labels on the Truck....7484
INTRODUCTION....7485
General....7487
Operating Instructions....7487
Service Training....7487
Ordering Spare Parts....7487
Using the Manual....7487
Page Numbering in the Manual....7488
Model Number....7490
LUBRICATION AND ADJUSTMENT....7491
Component Access....7493
Jacking up the Truck....7493
Lifting with a Crane....7493
Lifting by Truck....7494
Components....7495
Maintenance....7498
Driver Participation....7498
Daily Maintenance Log....7498
Recommended Lubricants and Oils....7498
Lubricants....7498
Cold Store Trucks....7498
Cold Store Trucks....7498
Table of Recommended Lubricants....7499
Check and Maintenance Schedule....7500
Daily or 8 hours....7500
Safety Reverse Switch – Functional Test....7502
Monthly or 100 hours....7504
3 months or 250 hours....7506
6 months or 500 hours....7506
Annually or 1.000 hours....7508
2 years or 2.000 hours....7508
Grease items and grease intervals....7510
Adjusting the Contact Pressure of Castors and the Drive Wheel....7512
Torques....7513
HYDRAULICS....7515
Hydraulic Symbols....7517
Hydraulic System....7521
Operation....7521
Removing the Hydraulic Unit WARNING....7522
Replacing the Hydraulic Pump....7523
Removal....7523
Installation....7523
Commissioning....7524
Pump Motor....7524
Filters....7524
Replacing the Pressure Filter....7524
Replacing the Suction and Return Filters....7524
Oil Change....7524
DRIVE UNIT....7527
Gear Unit....7529
Preparatory Measures....7529
Required Tools:....7529
Removal....7529
Maintenance....7529
General....7529
Gear Unit Disassembly / Assembly....7531
Assembly....7531
Preparing the Gear Unit....7531
Flange Shaft Assembly....7531
Pinion Shaft Assembly....7532
Adjusting the Bevel Gear Assembly....7532
Basic Rules:....7532
If necessary, reduce the torque. Checking the Flank Tooth Bearing....7532
Final Assembly....7532
Assembly....7533
Drive Motor....7533
ELECTRICS....7535
Electrics - General....7537
Electrics - General....7537
Wire Colour Codes....7537
Abbreviations....7538
Electrical Symbols....7540
Electrical Components....7541
Transmitter (POT, FS, RS)....7541
Fast / Slow Travel Switch (HSS)....7541
Safety Reverse Switch (SAS)....7541
Brake Switch (BRS)....7541
Tiller Position and Functions....7541
Illustrated Component Overview....7542
Illustrated Component Overview....7543
Lift / Lower Switch (RAS, LOS)....7544
Limit Switch (LMS)....7544
Horn Switch (HNS)....7544
Key Switch (KYS)....7544
Emergency Disconnect....7544
Fuses (FU)....7544
Temperature Switch (THS)....7544
Adjustment of Lift-Limit Switch....7544
SEM 1 Traction Controller....7545
General....7545
Precautionary Measures....7545
Operational Features....7545
Speed Control....7545
Reduced Speed Range....7545
Downhill Speed Control....7545
Regenerative Braking....7545
Anti - Roll Down Function....7545
Hourmeter....7546
Self Test....7546
Monitored Circuits....7546
Schematic, Monitored Circuits....7546
Protective Devices....7547
Polarity Protection....7547
Wiring Errors....7547
Temperature....7547
Start Sequence....7547
Safety Class....7547
Maintenance....7547
Traction Controller, Diagnostic Sheet....7548
SEM-1 Traction Controller Connections....7549
Power Connections....7549
Control Connections....7549
SEM-1 Pin Layout....7550
Status LED....7550
Descriptio of Alarms shown by LED....7551
Programmer....7552
Description of Keys....7553
Operating Menu SEM 1 Controller....7553
Operating Menu - Overview....7554
Menu Functions....7555
PARAMETER CHANGE....7555
TESTER....7555
ALARMS....7555
PROGRAM VACC....7555
CONFIG....7555
Settings....7556
Parameter Change Menu....7556
Adjustment of "MAX SPEED FRW W" and "MAX SPEED BCK W"....7557
Presets....7557
Measuring the speed....7557
Calculate the speed:....7557
TESTER Menu....7559
ALARMS Menu....7560
PROGRAM VACC Menu....7562
CONFIG Menu....7563
Traction Controller Safety Test....7564
Battery....7565
General....7565
Operation....7565
Reading the Electrolyte Level....7565
Replacing the Battery....7565
Removing the Battery....7565
Charging the Battery....7566
Battery Discharge Indicator (BDI)....7566
connection is secure. Adjusting the Battery Discharge Indicator....7566
Traction / Pump Motor Maintenance....7567
Access....7567
Maintenance....7567
BRAKE....7569
General Functional Description....7571
Removal....7571
Assembly....7572
Air Gap Setting....7572
Brake Moment Setting....7573
Brake Test....7573
Nominal Braking Distances and Screw Depth....7573
STEERING....7575
Multitask Handle - Springs for Return Function....7577
Adjustment....7577
Removal....7577
Assembly....7577
LIFTING MECHANISM....7579
Lift Linkage....7581
Fork Height Setting....7581
CYLINDERS....7583
Lift Cylinders....7585
Operation....7585
Removal....7585
Inspection....7587
Replacing the Piston Seal....7587
ELECTRICAL DIAGRAMS....7589
WP 2000-S STANDARD....7591
TRACTION CONTROLLER - LOGIC SIDE....7592
TRACTION CONTROLLER - POWER SIDE....7593
POWER UNIT CIRCUIT....7594
CONTROL HANDLE CIRCUIT....7595
WALKIE / RIDER CIRCUIT....7596
Power-Cables....7597
Main-Harness....7598
Handle-Harness....7599
WP 2000-S OPTIONS F/C....7600
TRACTION CONTROLLER - SEM1 LOGIC SIDE....7601
TRACTION CONTROLLER - ZAPI POWER SIDE....7602
POWER UNIT CIRCUIT....7603
CONTROL HANDLE CIRCUIT....7604
WALKIE / RIDER CIRCUIT....7605
HANDLE HARNESS F/ C....7606
HYDRAULIC SCHEMATIC....7607
HYDRAULIC SCHEMATIC....7609
WP2300....7612
WP2300....7612
REVISION....7614
Overview of Revisions....7614
TABLE OF CONTENT....7618
TABLE OF CONTENT 2....7619
TABLE OF CONTENT 3....7620
TABLE OF CONTENT 4....7621
TABLE OF CONTENT 5....7622
SAFETY....7626
Safety Symbols used in the Manual....7626
General Maintenance and Repair Safety Notes....7626
Maintenance and Repair....7626
Before Leaving the Truck....7627
Before Carrying out Work on the Truck....7627
Before Operating the Truck....7627
Warnings and Labels on the Truck....7627
INTRODUCTION....7630
General....7630
Operating Instructions....7630
Service Training....7630
Ordering Spare Parts....7630
Using the Manual....7630
Model-Number....7631
LUBRICATION AND ADJUSTMENT....7634
Component Access....7634
Jacking up the Truck....7634
Lifting by Crane....7634
Lifting by Truck....7635
Components....7636
Maintenance....7639
Recommended Lubricants and Oils....7639
Lubricants....7639
Cold Store Trucks....7639
Truck Decommissioning....7639
Restoring the Truck to Service....7639
Lybricant Type, Product Description, Manufacturer, CROWN-Part-No., Type....7640
Product, Product Name, Application, Crown Part No....7640
Check and Maintenance Schedule....7641
Daily or every 8 service hours....7641
Safety Reverse Switch – Functional Test....7643
Monthly or every 100 service hours....7645
Every 3 months or 250 service hours....7647
Every 6 months or 500 service hours....7647
Annually or every 1000 service hours....7649
Every 2 years or 2000 service hours....7649
Grease items and grease intervals....7651
Castors....7653
Torques....7654
Screw grade marking. Nut grade marking....7654
Standard Screws and Nuts....7655
Umbrako Screws and Nuts....7655
HYDRAULICS....7658
Hydraulic Symbols....7658
Hydraulic System....7662
Operation....7662
Removing the Hydraulic Unit....7663
Replacing the Hydraulic Pump....7664
Removal....7664
Installation....7664
Commissioning and Bleeding the System....7665
Pump Motor....7665
Filters....7665
Replacing the Pressure Filter....7665
Replacing the Suction and Return Filters....7665
Oil Change....7665
Replacing the Safety Valve....7667
Safety Valve Setting....7667
Safety Valve Test and Setting....7667
DRIVE UNIT....7671
Gear Unit....7670
Drive Unit, General....7671
Removing the Drive Unit....7671
Traction Motor Removal....7671
Dismantling the Motor....7672
Assembling the Motor....7672
Traction Motor Assembly....7674
Gear Unit Disassembly....7675
General....7675
Preparation....7675
Draining the oil....7675
Removing the drive unit....7675
Dismantling the gear unit lid....7675
Dismantling the gear unit....7676
Gear Unit Assembly....7676
Installing the gear unit lid....7678
Adding Oil....7678
Installing the drive unit....7678
ELECTRICS....7682
Electrics - General....7682
Wire Colour Codes....7682
Abbreviations....7683
Switch Symbol Abbrevation List....7683
Sundry Abbreviations....7684
Other Abbreviations....7685
Electrical Symbols....7685
Electrical Components....7686
Transmitter (POT, FS, RS)....7686
Fast / Slow Travel Switch (HSS)....7686
Reverse Safety Switch (SAS)....7686
Brake Switch (BRS)....7686
Override Switch (ORS)....7686
Raise / Lower Switch (RAS, LOS)....7687
Limit Switch (LMS)....7687
Horn Switch (HNS)....7687
Key Switch (KYS)....7687
Emergency Disconnect....7687
Fuses (FU)....7687
Thermal Switch (THS)....7688
SEM0 Traction Controller....7690
General....7690
Precautionary Measures....7690
Operational Features....7690
Speed Control....7690
Reduced Speed Ranges....7690
Downhill Speed Control....7690
Regenerative Braking....7690
Anti - Roll Down Function....7690
Hourmeter....7691
Self Test....7691
Monitored Circuits....7691
Protective Devices....7691
Polarity Protection....7691
Wiring Errors....7691
Temperature....7691
Start Sequence....7691
Safety Class....7691
Maintenance....7692
Replacing the SEM0 Traction Controller....7693
Parameter Setting after Replacing the Traction Controller....7693
Preparatory Measures....7693
Setting....7693
Status LED....7695
No. of Flashes, Console Display, Notes....7695
Programmer....7696
General....7696
Description of Keys....7697
Operating SEM0 Controller Menu....7697
General....7697
Operating Menu - Overview....7698
Menu Functions....7698
Settings and Alarms....7699
PARAMETER CHANGE Menu....7699
TESTER Menu....7700
ALARMS Menu....7701
ALARMS Menu (Contd.)....7702
PROGRAM VACC Menu....7702
ALARMS Menu (contd.)....7703
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu....7704
Preparatory Measures....7704
Calibration....7704
CONFIG Menu....7705
SET MODEL....7705
SET OPTIONS....7705
ADJUSTMENTS....7705
Traction Controller Safety Test....7706
Battery....7708
General....7708
Replacing the battery....7708
Battery Discharge Indicator (BDI)....7708
General....7708
Battery Discharge Indicator Setting (BDI)....7709
Calibration....7709
Discharge Terminal Voltage Setting in Volts/Cell....7709
On Board Charger....7710
General....7710
Battery Charging Phases....7710
Special Charging Phases....7710
Charging Errors....7711
Green LED is not lit....7711
Green LED flashing....7711
Charging Phases....7711
Electric Motors....7714
General Maintenance Instructions....7714
Preparation....7714
Important Maintenance Instructions....7714
Traction Motor Maintenance....7715
Access to Brushes....7715
Maintenance....7715
Armature....7715
Bearings....7715
Pump Motor Maintenance....7716
Access to brushes....7716
Maintenance....7716
Armature....7716
BRAKE....7720
Operation....7720
Removal....7720
Assembly....7722
Air Gap Setting....7722
Brake Moment Setting....7722
Testing the Brakes....7722
Nominal Braking Distance (unladen)....7722
STEERING....7726
Live Ring Bearing....7726
Disassembly....7726
Installation....7726
Multitask Handle - Springs for Return Function....7727
Adjustment....7727
Removal....7727
Assembly....7727
Tiller Handle....7728
Main Components....7728
Tiller Handle Component Removal / Installation....7729
Tiller Handle Shells....7729
Removing the Upper and Lower Shells....7729
Fitting the Upper and Lower Shells....7730
Switch Unit....7731
Removal....7731
Switch Unit Installation....7731
"Fast/Slow" Toggle Switch....7732
Removal....7732
Installation....7732
Hydraulic Board....7732
Removal....7732
Installation....7732
Potentiometer....7733
Removal....7733
Installation....7733
Safety Reverse Switch....7734
Removal....7734
Installation....7734
Horn Switch....7735
Removal....7735
Installation....7735
Handle....7736
Removal....7736
Installation....7736
Lift Linkage....7740
Fork Height Setting....7740
CYLINDERS....7744
Lift Cylinders....7744
Operation....7744
Removal....7744
Inspection....7746
Replacing the Piston Seal....7746
DIAGRAMS....7750
Overall Wiring Diagram, Standard Version....7750
Overall Wiring Diagram with Options....7751
Wire harness overview, all versions....7752
HYDRAULIC CIRCUIT....7756
WP2300S....7758
WP2300S....7758
REVISION....7760
TABLE OF CONTENT....7764
Table of Content 1....7764
Table of Content 2....7765
Table of Content 3....7766
Table of Content 4....7767
Table of Content 5....7768
Table of Content 6....7769
SAFETY....7772
Safety Symbols used in the Manual....7772
General Maintenance and Repair Safety Notes....7772
Maintenance and Repair....7772
Before Leaving the Truck....7773
Before Carrying out Work on the Truck....7773
Before Operating the Truck....7773
Warnings and Labels on the Truck....7773
INTRODUCTION....7776
General....7776
Operating Instructions....7776
Service Training....7776
Ordering Spare Parts....7776
Using the Manual....7776
Model-Number....7777
LUBRICATION AND ADJUSTMENT....7780
Jacking up the Truck....7780
Raising the Truck with a Crane....7780
Fixed Platform....7780
Folding Platform....7781
Both Platforms....7782
Raising with a Forklift Truck....7783
Component Access and Components....7784
Maintenance....7787
Recommended Lubricants and Oils....7787
Lubricants....7787
Cold Store Trucks....7787
Truck Decommissioning....7787
Restoring the Truck to Service....7787
Lubricant Type, Product Description, Manufacturer, Crown Part No., Type....7788
Product, Product Name, Application, Crown Part No....7788
Check and Maintenance Schedule....7789
Daily or every 8 service hours....7789
Safety Reverse Switch – Functional Test....7791
Monthly or every 100 service hours....7793
Every 3 months or 250 service hours....7795
Every 6 months or 500 service hours....7795
Annually or every 1000 service hours....7797
Every 2 years or 2000 service hours....7797
Grease items and grease intervals....7799
Adjusting the Contact Pressure of the Castors and the Drive Wheel....7801
Procedure:....7801
Calculating the Adjustment Required:....7801
Example:....7801
Torques....7802
Screw grade marking. Nut grade marking....7802
Standard Screws and Nuts....7803
Umbrako Screws and Nuts....7803
HYDRAULICS....7806
Hydraulic Symbols....7806
Hydraulic Symbols 1....7806
Hydraulic Symbols 2....7807
Hydraulic Symbols 3....7808
Hydraulic Symbols 4....7809
Hydraulic System....7810
Operation....7810
Removing the Hydraulic Unit....7811
Replacing the Hydraulic Pump....7812
Removal....7812
Installation....7812
Commissioning and Bleeding the System....7812
Pump Motor....7814
Filters....7814
Replacing the Pressure Filter....7814
Replacing the Suction and Return Filters....7814
Oil Change....7814
Replacing the Safety Valve....7815
Safety Valve Setting....7815
Safety Valve Test and Setting....7815
Testing and Setting the Load-Dependent Pressure Switch....7816
DRIVE UNIT....7820
Gear Unit....7820
Preparatory Measures....7820
Required Tools:....7820
Removal....7820
Maintenance....7820
General....7820
Gear Unit Disassembly / Assembly....7822
Disassembly....7822
Assembly....7822
Preparing the Gear Unit....7822
Flange Shaft Assembly....7822
Pinion Shaft Assembly....7823
Adjusting the Bevel Gear Assembly....7823
Basic Rules:....7823
Checking the Flank Tooth Bearing....7823
Final Assembly....7823
Assembly....7824
Drive Motor....7824
ELECTRICS....7828
Electrics - General....7828
Wire Colour Codes....7828
Abbreviations....7829
Switch Symbol Abbreviation List....7829
Sundry Abbreviations....7830
Other Abbreviations....7831
Electrical Symbols....7831
Electrical Components....7832
Travel Switch (POT, FS, RS)....7832
Fast/Slow Switch (HSS)....7832
Safety Reverse Switch (SAS)....7832
Brake Switch (BRS)....7832
Brake Switch (BRS) Used from serial no. 5A336576, except for 5A337937....7832
Raise/Lower Switch (RAS, LOS)....7833
Pressure Switch (PS)....7833
Platform Control Switches (GCSR, GCSL, PLS)....7833
Lift Limit Switch (LMS)....7833
Horn Switch (HNS)....7833
Foot Switch (FTS)....7833
Key Switch (KYS)....7833
Emergency Disconnect (BD)....7833
Fuses (FU)....7833
Thermal Switch (THS)....7833
Filter (WP2340S only)....7833
Diode D4....7833
Diode block (DB)....7833
Platform Logic (PLM) Used from serial no. 5A336576, except for 5A337937....7834
WP2330S....7835
WP2330S PLM Used from serial no. 5A336576, except for 5A337937....7836
WP2335S....7837
WP2340S....7838
Battery....7840
General....7840
Replacing the battery....7840
Battery Discharge Indicator (BDI)....7840
General....7840
Battery Discharge Indicator Setting (BDI)....7841
Calibration....7841
Discharge Terminal Voltage Setting in Volts/Cell....7841
SEM1 Traction Controller....7842
General....7842
Precautionary Measures....7842
Operational Features....7842
Speed Control....7842
Reduced Speed Ranges....7842
Downhill Speed Control....7842
Regenerative Braking....7842
Anti - Roll Down Function....7842
Hourmeter....7843
Self Test....7843
Monitored Circuits....7843
Protective Devices....7843
Polarity Protection....7843
Wiring Errors....7843
Temperature....7843
Start Sequence....7843
Safety Class....7843
Maintenance....7844
Replacing the SEM1 Traction Controller....7845
Parameter Setting after Replacing the Traction Controller....7845
Preparatory Measures....7845
Setting....7845
Status LED....7847
Programmer....7848
General....7848
Description of Keys....7849
Operating SEM1 Controller Menu....7849
General....7849
Menu Functions....7849
PARAMETER CHANGE....7849
TEST....7849
ALARMS....7849
PROGRAM VACC....7849
CONFIG....7849
Menu Structure for Folded Platform....7850
Menu Structure for Fixed Platform....7851
Parameter Setting, Folded Platform....7852
Parameter Change Menu, folded Platform, SW#006B....7852
Parameter Change Menu, folded Platform, SW#006B....7853
Parameter Setting, for Trucks with a Folded Platform, 02 Rev. 05/05....7854
Parameter Change Menu, folded Platform, SW#006B....7854
Parameter Setting, Fixed Platform....7853
Parameter Change Menu, fixed Platform, SW#105....7853
Parameter Setting, for Trucks with a Fixed Platform, 02 Rev. 05/05....7854
Parameter Change Menu, fixed Platform, SW#105....7854
Parameter Change Menu, fixed Platform, SW#105....7856
TESTER Menu....7857
ALARMS Menu....7858
ALARMS Menu ....7858
ALARMS Menu (Contd.)....7859
ALARMS Menu (Contd.)....7860
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu....7861
Preparatory Measures....7861
Calibration....7861
CONFIG Menu....7862
SET MODEL....7862
SET OPTIONS....7862
ADJUSTMENTS....7862
Traction Controller Safety Test....7863
Troubleshooting....7864
Platform LogicController PN 815144....7864
WP2300S Platform Logic Box, M502....7864
Electric Motors....7866
General Maintenance Instructions....7866
Preparation....7866
Important Maintenance Instructions....7866
Traction Motor Maintenance....7867
Access to Brushes....7867
Maintenance....7867
Armature....7867
Bearings....7867
Pump Motor Maintenance....7868
Access to brushes....7868
Maintenance....7868
Armature....7868
BRAKE....7872
Brake....7872
Removal....7872
Disassembly....7873
Test and Inspection....7873
Assembly....7873
Assembly....7874
Air Gap Setting....7874
Brake Moment Setting....7875
Testing the Brakes....7875
WP2300S Nominal Breaking Distances and Screw Depth....7875
STEERING....7878
Multitask Handle - Springs for Return Function....7878
Adjustment....7878
Removal....7878
Assembly....7878
Control Handle Grip....7880
Main Components....7880
Hand grip component removal and assembly....7881
Hand Grip Shells....7881
Upper and lower shell removal....7881
Upper and lower shell assembly....7882
Switch Unit....7883
Disassembly....7883
Switch unit assembly....7883
“Rabbit/Turtle” toggle switch....7884
Disassembly....7884
Assembly....7884
Hydraulic PC board....7884
Disassembly....7884
Assembly....7884
Main PC Board Removal/Installation....7886
Potentiometer....7887
Disassembly....7887
Assembly....7887
Safety Reverse Switch....7888
Disassembly....7888
Assembly....7888
Horn switch....7889
Disassembly....7889
Assembly....7889
Hand Grip....7890
Disassembly....7890
Assembly....7890
LIFTING MECHANISM....7894
Lift Linkage....7894
Fork Height Setting....7894
Lift Limit Cutout....7896
Lift Limit Cutout Setting....7896
CYLINDERS....7900
Lift Cylinders....7900
Operation....7900
Removal....7900
Inspection....7902
Replacing the Piston Seal....7902
PLATFORM....7906
Folding Platform....7906
Mechanical Setting....7906
Platform Switch Setting (PLS)....7907
Platform Suspension....7908
Plate Spring Layers....7908
Side Gates, Mechanical Setting....7909
Fixed Platform WP2335S....7910
Replacing the Safety Switch....7910
Fixed Platform WP2340S....7911
Replacing the Safety Switch....7911
Fixed Platform WP2340S....7912
Replacing Switches below the Entry Bars (FPS 1 & FPS 2)....7912
ELECTRICAL DIAGRAMS....7914
WP2330S....7917
Notes to overall wiring diagram, standard version, folded platform, WP2330S....7917
Overall Wiring Diagram, Standard, Folded Platform, WP2330S....7918
SCHEMATIC DIAGRAM....7919
TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT....7919
TRACTION CONTROLLER - SEM1 POWER CIRCUIT....7920
PLATFORM CIRCUIT....7920
POWER UNIT CIRCUIT....7921
CONTROL HANDLE CIRCUIT....7921
PLATFORM LOGIC....7922
Notes to overall wiring diagram, standard version, fixed platform WP2330S....7923
Overall Wiring Diagram, Folded Platform with Options WP2330S....7924
WP2330S OPTIONS, FOLDED PLATFORM SCHEMATIC DIAGRAM....7925
WP2330S STANDARD, FOLDED PLATFORM TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT....7925
WP2330S STANDARD, FOLDED PLATFORM, TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT....7926
WP2330S STANDARD, FOLDED PLATFORM, PLATFORM CIRCUIT....7926
WP2330S OPTIONS, FOLDED PLATFORM, POWER UNIT CIRCUIT....7927
WP2330S STANDARD, FOLDED PLATFORM, CONTROL HANDLE CIRCUIT....7927
WP2330S STANDARD, FOLDED PLATFORM, PLATFORM LOGIC....7928
WP2335S....7929
Notes to overall wiring diagram, Standard Version, Fixed platform WP2335S....7929
Overall Wiring Diagram, Standard, Fixed Platform WP2335S....7930
Notes to overall wiring diagram, with options, fixed platform, WP2335S....7931
Overall Wiring Diagram, Fixed Platform with Options WP2335S....7932
WP 2340S....7933
WP 2340S STANDARD, FIXED PLATFORM SCHEMATIC DIAGRAM....7933
WP 2340S STANDARD, TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT....7933
WP 2340S STANDARD, POWER CIRCUIT - TRACTION & PUMP MOTOR....7934
WP 2340S STANDARD, FIXED PLATFORM, PLATFORM CIRCUIT....7934
WP 2340S STANDARD, FIXED PLATFORM, POWER UNIT CIRCUIT....7935
WP 2340S STANDARD, FIXED PLATFORM, CONTROL HANDLE CIRCUIT....7935
WP 2340S OPTIONS, FIXED PLATFORM, SCHEMATIC DIAGRAM....7936
WP 2340S OPTIONS, FIXED PLATFORM, TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT....7936
WP 2340S OPTIONS, FIXED PLATFORM, POWER CIRCUIT - TRACTION & PUMP MOTOR....7937
WP 2340S OPTIONS, FIXED PLATFORM, PLATFORM CIRCUIT....7937
WP 2340S OPTIONS, FIXED PLATFORM, POWER UNIT CIRCUIT....7938
WP 2340S OPTIONS, FIXED PLATFORM, CONTROL HANDLE CIRCUIT....7938
Wire harness overview, folded platform, WP2330S all versions....7939
Main Harness, Folded Platform, WP2330S, All Versions....7940
Control Handle - Wire Harness, Folded Platform, WP2330S, All Versions....7941
Horn Switch - Wire Harness, Folded Platform, WP2330S, All Versions ....7942
Wire Harness Overview, Fixed platform, All versions....7943
Wire Harness Overview, Fixed Platform, WP2340S, All Versions....7944
Control Handle - Wire Harness, Fixed Platform, WP2340S, All Versions....7945
Horn Switch - Wire Harness, Fixed Platform, WP2340S, All Versions....7946
Cables, Platform, Fixed Platform, WP2340S, All Versions....7947
Power Cables....7948
HYDRAULIC CIRCUIT....7952
Crown Forklifts Models Service Repair Manuals
